Install/Upgrade to 4" Snorkel (recessed) and new Pod Air Box

[Bidja]

Replacing my 3" Safari snorkel with a 4" SS recessed snorkel and will also install a new airbox (w/K&N 9" pod filter).

Getting tools together to cut out 4" clearance hole thru inner guard and also the elongated hole req'd in the guard for placement of recessed snorkel. Might buy an air operated "Body (panel) Saw" to open out the entry holes.



Aluminium template is provided with the air box, that can be secured/bolted in place against inner guard and can be used as a guide to cut / enlarge the box entry hole. Yes could use hole saw set up but don't have suitable size. Need to also cut out a section of the radiator shroud/cowl as well.

Any one used a body saw for panel cutting and how do they finish off job?

Could buy a nibbler but thought the body saw may be a good tool option and produce less metal corrosive chips/swarf that could prove difficult to remove.

[Hodge]

Watching this with interest, as I'll be doing the same in new year.
Bidja. Have a look at MudRunnerTD 's post #429. It might give you some idea .
http://www.nissanpatrol.com.au/forum...l=1#post764801

[Bidja]

Saw that post, sound as she performs but don"t want to pop my flare though....

[Bidja]

Like this concept demonstrator that Darren stumbled across (snorkel spotting)..haha.

[MudRunnerTD]

Saw that post, sound as she performs but don"t want to pop my flare though....

Yeah i stuffed around and struggled for a couple ofhours before i popped the flare. It opened it right up and made the job 10 times easier. Pop the flare. Even if you break the clips they are cheap.

I used a set of yellow, green and red tin snips to cut the recess by hand.

[Bidja]

Yeah i stuffed around and struggled for a couple ofhours before i popped the flare. It opened it right up and made the job 10 times easier. Pop the flare. Even if you break the clips they are cheap.

I used a set of yellow, green and red tin snips to cut the recess by hand.

Thought you popped the flare when you were in close proximity to a neighboring a bull bar?

Good job with the snips there mate.

Buy the way, checked out Supercheap for lip seal removal hook tool(front inner axle seal), was going to make one out of 3mm plate, but they sent me an email yesterday and said they hadn't seen me for a while and gave me $10 credit voucher for use by COB today. So just then, went online and bought one from them $13 (sweet as).

[MudRunnerTD]

Thought you popped the flare when you were in close proximity to a neighboring a bull bar?

Good job with the snips there mate.

Buy the way, check out Supercheap for lip seal removal hook tool(front inner axle seal), was going to make one out of 3mm plate, but they sent me an email yesterday and said they hadn't seen me for a while and gave me $10 credit voucher for use by COB today. So just then, went online and bought one from them $13 (sweet as).

Bloody @AB is a hoon. Nah i popped that flare half way through the job in frustration cause i simply could get the 4" in. Made a huge differences

[Bidja]

Yeah i stuffed around and struggled for a couple ofhours before i popped the flare. It opened it right up and made the job 10 times easier. Pop the flare. Even if you break the clips they are cheap.

I used a set of yellow, green and red tin snips to cut the recess by hand.

Darren, finally got all my bits to do snorkel and airbox install. Have finally had success in removing heat shield over turbo to replace gasket between turbo and dump pipe and wrap. Waiting on some wurth nuts.

Can easly cut 125mm hole in inner guard (next to airbox), but what did you do for the second panel skin hole to suit 4" elbow to snorkel straight duct?

Problem gone away - job done

[Bidja]

Now with all bits on hand, have commenced the install of the 4" thru air box / 9" K&N pod filter (post #11) and the 4" fwd facing recessed SS snorkel (with 4" Safari Air Ram Hd).

There are many install methods and product types to do satisfy this install and they all have their limitations.

This thread details the method that I adopted as a DIY project and is provided for information purposes only for those interested. I will document as I progress.

The available space in my eng bay is limited having JT TMIC(606x300x76mm core). Have to shift my catch can (that was under induction pipe near air box to turbo) and a marine rotary switch that I use to select either or both aux batteries (vehicle or in tow) and need to buy a smaller one and relocate it to allow for relocation of the catch can.
At the same time, removing dump pipe as the gasket from turbo to dump is leaking, will wrap dump while out and now just waiting on Wurth nuts. Was a job to remove the heat shield, one bolt had ceased due to heat.

[Bidja]

Watching this with interest[/IMG]

Sent you a PM mate.