Contour Enthusiasts Group Archives Forums Modifications Zetec Performance The BP CAI is finished! Beware 56k.

Well after a year of planning and buying parts it is finally finished. Parts list...

1 - 2.75" 90 degree elbow
1 - 2.75" to 3" transition (for throttle body)
3 - 3" 45 degree elbows
1 - 3" 90 degree elbow
1 - 3.25" to 3" transition (for MAF)
2 feet of 3" tubing
2 inches of 2.75" tubing
'00 Contour MAF (or '00 Contour )
3/4" Aluminum flat Bar for MAF bracket (I reused my CTA bracket)
15 - 3" hose clamps
3.25" hole saw

I haven't tallied it up but I'm guessing that it cost me around $250. BTW, I also built a custom jig to cut the silicone hose. I'll post a pic of that later.

And now the pics...

Entire intake from the front:


Entire intake from the side:


Throttle body to MAF:


MAF to filter:


Angled pic of MAF to filter (showing filter clamp):


CTA bracket supporting MAF:



<<<More pics for your viewing pleasure>>>


The only tube that is showing is 7" long (5" showing). All of the other tubes were only 2" long. (Just enough to connect the silicone parts together.)

I also replaced my '96 MAF with a '00 MAF. This was because the '00 MAF has the IAT built into the MAF. That way I didn't have to drill a hole for the IAT into any of the pipes. You can barely tell huh? I even got some 3/8" split loom to match to stock stuff as close as possible.

The only thing that I don't like is the the 45 degree elbow that connects to the air filter is bent at more of a 60 degree angle. This slightly flattens out that bend. It isn't much but it still bugs me.

Also, I drilled the 3.25" hole in the body using one of the old battery tray mounting holes as my center (pilot) hole. This was soo perfect that it was scary. I also used some rubber grommet to finish the hole.

BTW, I am currently re-using the CTA filter. I am planning on ordering a filter that properly fits a 3" piece of pipe.

It also helps to unbolt the horn to get into the filter area under the car.

I'm tired so I hope that this makes sense.

BTW #2, this intake sounds AWESOME!!! It has a much lower tone than the CTA. It matches my exhaust perfectly.

BTW #3, I know my engine bay is dirty. Bite me.

Later,
Ben

Before anybody asks...

How I relocated my battery.


BP

wow I'm jealous...that looks way better than mine. And your hole is much cleaner too, good job!

Looks good! I'm sure you couldn't get any decent shots, since it was dark, but I would really like to see some shots from underneath.

Very nice, do u think it was worth the money u spent

Thanks everybody!

Considering that there aren't any true CAI's for our cars, I think that it was well worth the cash. I'll have to total it all up.

I'll also get some underside pics and pics of the hose cutting jig posted.

Later,
Ben

WOW I didn't realize how much that this cost until I added it all up. $364.17 (not including MAF) I guess that it helps that I bought the parts over a year's time period.

If I had bought the cheaper silicone parts from Overboost.com I could have saved a chunk of change. But they only have black and red hoses. Not much blue. If I had used substitute parts from Overboost, it would have cost me $275.86. Doh!

Parts list with sources...

1 - 2.75" 90 degree elbow $42 from Baker Precision
1 - 2.75" to 3" transition (for throttle body) $21 from Baker Precision
3 - 3" 45 degree elbows $45 from Baker Precision
1 - 3" 90 degree elbow $45 from Baker Precision
1 - 3.25" to 3" transition (for MAF) $35.37 from Turbo Hoses
2 feet of 3" Stainless tubing $22 from ATP Turbo
2 inches of 2.75" Aluminum tubing $18 from ATP Turbo
'00 Contour MAF (or '00 Contour) $45 from local junkyard
3/4" Aluminum flat Bar for MAF bracket - Reused my CTA bracket
15 - 3" hose clamps $3.05 from Turbo Hoses
3" Air Filter - Reused from CTA intake

Hey Ben..i could dupliacte that intake outta of mandrel bends from JC Whitney probably quite cheaply. It would be Mild steel but a little paint goes a far way. Use your current setup as a jig and you could make some $$$$ on your felllow zetec cegers