DIY -Ryco A360 flat panel airbox with 4" in/out

[jff45]

I've just made my own flat panel airbox with 4" in/out and thought it might interest some of you.
For space reasons I chose the Ryco A360 air filter. This is standard on some old VN & VS Commodores and also the GQ TB42E and some Nissan Skylines.

I got a 600 x 600 x 1.6mm sheet of mild steel from Bunnings and a couple of 4" mandrel bends from Ebay but only used cuts from the 45 degree.
I can't weld aluminium so I'm making it all in mild steel and welding with a MIG.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160203_IMG_3829_zpsnjglfmw0.jpg

Made a mockup from card board.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3843_zpsggwlip9z.jpg

Drew it on the steel plate and plasma cut it with my little Ebay cutter.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3847_zps8ivkjrr1.jpg

Bent it into shape.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3852_zpsdpzmxfju.jpg

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3851_zpsf0ys1koc.jpg

Then I made the lid. The shape was decided by the height to fit under bonnet and the A/C & steering hoses.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3858_zpsg7fmal8r.jpg

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3857_zpsizczkggf.jpg

Welded on the outlet pipe and did some trial positioning.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160207_IMG_3869_zpsa7mmsufw.jpg

I then welded a 15x3mm skirt around the lid that serves as the lip that tightens down onto the filter edge.
Welded some fixing tabs and painted it all ready to go.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160211_IMG_3887_zpspvjfwjbd.jpg

All bolted in.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160211_IMG_3892_zpsl6zx4feb.jpg

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160213_IMG_3900_zpsvc009mv0.jpg

Cost came out under $200 including steel, A360 element and silicone hoses & clips

I still need to cut a bigger opening in the inner guard to have a 4" elbow coming through.
I plan to retain the current Nissan snorkel.

[MudRunnerTD]

Wicked!!!!!

[lucus30]

thats a shit hot job mate. Very impressive

[Winnie]

Very very nicely done!
Wish I could weld.

[lucus30]

Welcome to come round here any time and learn. I'm new to welding myself

[lhurley]

Where abouts did you get the 4" pipe from? Have a few ideas rolling around in my head that I want 4" pipe for

[jff45]

As I mentioned above, metal sheet from Bunnings and 4" mandrel bends from Ebay..

[mudnut]

That is truly a great looking piece of work.

[Bloodyaussie]

Top notch as always mate.

[lucus30]

I've just made my own flat panel airbox with 4" in/out and thought it might interest some of you.
For space reasons I chose the Ryco A360 air filter. This is standard on some old VN & VS Commodores and also the GQ TB42E and some Nissan Skylines.

I got a 600 x 600 x 1.6mm sheet of mild steel from Bunnings and a couple of 4" mandrel bends from Ebay but only used cuts from the 45 degree.
I can't weld aluminium so I'm making it all in mild steel and welding with a MIG.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160203_IMG_3829_zpsnjglfmw0.jpg

Made a mockup from card board.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3843_zpsggwlip9z.jpg

Drew it on the steel plate and plasma cut it with my little Ebay cutter.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3847_zps8ivkjrr1.jpg

Bent it into shape.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3852_zpsdpzmxfju.jpg

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3851_zpsf0ys1koc.jpg

Then I made the lid. The shape was decided by the height to fit under bonnet and the A/C & steering hoses.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3858_zpsg7fmal8r.jpg

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/IMG_3857_zpsizczkggf.jpg

Welded on the outlet pipe and did some trial positioning.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160207_IMG_3869_zpsa7mmsufw.jpg

I then welded a 15x3mm skirt around the lid that serves as the lip that tightens down onto the filter edge.
Welded some fixing tabs and painted it all ready to go.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160211_IMG_3887_zpspvjfwjbd.jpg

All bolted in.

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160211_IMG_3892_zpsl6zx4feb.jpg

http://i257.photobucket.com/albums/hh207/JFF45/Conversion/Airbox/20160213_IMG_3900_zpsvc009mv0.jpg

Cost came out under $200 including steel, A360 element and silicone hoses & clips

I still need to cut a bigger opening in the inner guard to have a 4" elbow coming through.
I plan to retain the current Nissan snorkel.

Actually I just noticed something very wrong in these photos

[jff45]

The fact that I drink diet coke? :)

[jff45]

I was previously using the stock GU TD42 airbox with the cobra head mod and 3" pipe down to turbo into 2.5" reduction.
I still have the stock HT18 turbo so wasn't expecting to feel much, if any, difference.
I was surprised to find it pulls better earlier and I gained 1.5 PSI, from 11 to 12.5.
It would previously sort of let you know that it wasn't real keen on going much past 3000 rpm but now it goes to 4000 with much less hesitation.
This is simply with the airbox and bigger intake. No other adjustments to anything.
The auto shifts under a bit more boost feel really nice. Makes it even more drivable than before.
Looking forward to fitting a Mamba turbo now..

[lucus30]

The fact that I drink diet coke? :)

ha ha yeah

[nissannewby]

I was previously using the stock GU TD42 airbox with the cobra head mod and 3" pipe down to turbo into 2.5" reduction.
I still have the stock HT18 turbo so wasn't expecting to feel much, if any, difference.
I was surprised to find it pulls better earlier and I gained 1.5 PSI, from 11 to 12.5.
It would previously sort of let you know that it wasn't real keen on going much past 3000 rpm but now it goes to 4000 with much less hesitation.
This is simply with the airbox and bigger intake. No other adjustments to anything.
The auto shifts under a bit more boost feel really nice. Makes it even more drivable than before.
Looking forward to fitting a Mamba turbo now..

This is why i continue to tell people not to stuff about with the factory one. Whichever way you go it is better to just get something better.

[Cuppa]

Professional looking job. Nice one!

[jff45]

This is why i continue to tell people not to stuff about with the factory one. Whichever way you go it is better to just get something better.

Shhhhht, I'm trying to sell my old one :)

[Bloodyaussie]

Shhhhht, I'm trying to sell my old one :)

I was going to make you an offer but no way now.... pfft some mate youve got there heh matty. ... ha ha ha ha!!!!!

At my new job there is a guillotine and sheet metal folder and my brain is ticking with ideas.

[threedogs]

Very nice work, you could make a lot of $$$ pricing these right, again great work,
have to be happy with that,, lol

[jff45]

Very nice work, you could make a lot of $$$ pricing these right, again great work,
have to be happy with that,, lol

I wouldn't bother, I'm enjoying my retirement doing stuff for myself..

[threedogs]

I wouldn't bother, I'm enjoying my retirement doing stuff for myself..

Thinking a bit of extra petrol money lol
But again well thought out you must be happy

[mudski]

Wow! Mate if you wanna make some extra coin in your own time, ill buy one off ya. I could make one too but i just dont have the time to remove the air box and measure everything up. I need my wheels everyday.

Sent from my SM-P600 using Tapatalk

[jff45]

Wow! Mate if you wanna make some extra coin in your own time, ill buy one off ya. I could make one too but i just dont have the time to remove the air box and measure everything up. I need my wheels everyday.

Sent from my SM-P600 using Tapatalk

Mark, the main issue is that my vehicle is a bit unique with the steering pump on the left side and the TB45 A/C hoses running differently to a stock TD42T.
There's also an issue of battery tray which I don't have.
All that means that I'd have to have access to the vehicle to get it right.

There are several fabricators who do nice alloy boxes.

[mudski]

Yeah i just noticed you dont have the second battery... i can weld pretty good but dont have access to a cutter or bender. Ah well.
Kudos on your effort mate though. Bloody well done.

Sent from my SM-P600 using Tapatalk

[Hodge]

That is very nice John. The fact you noticed some difference makes it all worthwhile.
Well done.

[jff45]

Shhhhht, I'm trying to sell my old one :)

Well, looks like I just sold it :)

[mudski]

Who's intake manifold do I see in the pic mate?

[jff45]

Who's intake manifold do I see in the pic mate?

P4x4 member mytqik did it for me.

[mudski]

P4x4 member mytqik did it for me.

You seen those Plazman Manifolds? Billet and look real nice! They got a nice price tag to go with it too...

You should be proud of your efforts mate. On everything you have done in the engine bay... If your not already. Real quality custom work there.

[jff45]

You should be proud of your efforts mate. On everything you have done in the engine bay... If your not already. Real quality custom work there.

Cheers Mark, yes I'm pretty happy with it now. There's nothing really hard to do in there if you have the time and can weld a bit.
The IC cradle is only 20mm square tube and some flat bar. The IC inlet pipe is a piece of painted exhaust.

I guess I have the patience of my age :)

[mudski]

More than patience there mate. :)

Sent from my SM-P600 using Tapatalk

[lucus30]

How did you bend the sheet? Have you got a bender or you do it a different way

[jff45]

How did you bend the sheet? Have you got a bender or you do it a different way

I have a length of angle iron fixed to my press to work like a homemade panbrake.
I bent the small end in my vice. It's only 1.6mm same as exhaust pipe
...

[lucus30]

Nice!!! I'll swap workshops with you ha ha

[mudski]

I have a length of angle iron fixed to my press to work like a homemade panbrake.
I bent the small end in my vice. It's only 1.6mm same as exhaust pipe
...

I got the same press. By mine is red. I'm trying to work out how to bent that sheet....

[jff45]

Are you asking how it works?

[mudski]

Are you asking how it works?
Hmm yeah for curiosity. If it doesnt take too many words to do. :)

Sent from my SM-P600 using Tapatalk

[jff45]

If you look at the 2nd pic, you'll see one side of the box bent up. The angle iron swings up 90 degrees.
The press is holding the rest of the sheet firm while a side is bent up.
If you look closely, you'll see a steel tube sticking out under the angle iron. I put a round steel bar in there to lift the angle iron up.
It's the principle of a panbrake but a bit ghetto..

In the 1st pic you can see the bolts in line with the edge if the angle so it pivots along that line.

[mudski]

Gotcha, so the angle iron pivots upward to bend the plate, and the press holds the plate down. Ingenious.

[jff45]

Finally got the 4" elbow through the inner guard. Tried to do it all from the engine side but you can't do a neat job without removing the mudguard.
It was easier than I'd thought to remove.
This elbow gets rid of a restriction that the last bend of the snorkel has.
...

[MudRunnerTD]

can you post a pic of the seat for the filter? is it founded on the edge of the lower box or s there a rebate folded there? i can't quite make it out? Also some dimensions on that unfolded flat plate would be wicked! i am very keen to adapt this to something for my GQ.

[threedogs]

I brought this as a press but throwing it out now as having a huge clean up like BA

[jff45]

The 1.6mm edge of the lower half has a 3mm flat bar border welded around it so the filter is effectively sitting on a 4.6mm edge.
...

[jff45]

From a different angle
...

[jff45]

For the dimensions, I'm not sure it's a good idea to copy this sort of thing exactly.
It took me 10 mins to make the cardboard mock up but I trimmed it a fair bit with scissors to make it fit right.
I first cut a piece the same size as the filter to make sure I didn't buy a filter I couldn't use.
Once you have it right, it's easy to transfer the shape to metal, especially as the width will be the width of the filter anyway

[jff45]

Here's the inside of the lid
...

[MudRunnerTD]

Very helpful. Cheers. And the panel filter you chose? Why that one? Size? Price? Availability? Sorry what is it out of? You probably have that in the first post!

[MudRunnerTD]

So I could probably fold that edge rather than welding a strip.

[MudRunnerTD]

Very helpful. Cheers. And the panel filter you chose? Why that one? Size? Price? Availability? Sorry what is it out of? You probably have that in the first post!

Just re read the first post. Cheers. Great thread mate.

[jff45]

So I could probably fold that edge rather than welding a strip.

Yes, certainly. The added strip was easier for me to do than bending

[Enthree]

now thats some nice fabrication! good work

[Touses]

I wouldn't bother, I'm enjoying my retirement doing stuff for myself..

Heya bloke! If you still have the pattern and I can induce you to build another I'd be happy to part with the necessary.

Perhaps just pay you for a copy of the pattern? :smiley_thumbs_up:

[mudski]

Heya bloke! If you still have the pattern and I can induce you to build another I'd be happy to part with the necessary.

Perhaps just pay you for a copy of the pattern? :smiley_thumbs_up:

Johns certainly done such a professional job on the air box hey? I'm still gobsmacked with his work.

[jff45]

Cheers Mark, I'm still not interested in making one for someone else :)

You'd be surprised how simple it is if you buy a filter, grab some cardboard and ducting tape and get to work with the scissors.
This thread was meant to provide inspiration so get inspired and get stuck into it :)

[jff45]

I should add, it seems to be working really well with the Mamba (TD05H copy) 16G/6cm I've just fitted.
Hitting 22 psi easily with not too much induction noise

[Touses]

Cheers Mark, I'm still not interested in making one for someone else :)

You'd be surprised how simple it is if you buy a filter, grab some cardboard and ducting tape and get to work with the scissors.
This thread was meant to provide inspiration so get inspired and get stuck into it :)

Ok so I can't buy my way out of this one. In that case I shall become inspired and have a crack!
Bandages, check. Eye wash, check. Ambulance on speed dial, check. All set! :smile:

[Shipo]

Very nice work buddy! Very impressed espicially with limited tools...
Just wondering if u have tested how well it seals???

[Rip'n'Shred]

As if the DIY air box wasn't enough inspiration to build, you go and throw in the DIY panbrake too! Thanks for the efforts of the writeup! You inspired me.