E46 BMW Social Directory E46 FAQ 3-Series Discussion Forums BMW Photo Gallery BMW 3-Series Technical Information E46 Fanatics - The Ultimate BMW Resource BMW Vendors General E46 Forum The Tire Rack's Tire Wheel Forum Forced Induction Forum The Off-Topic The E46 BMW Showroom For Sale, For Trade or Wanting to Buy

Welcome to the E46Fanatics forums. E46Fanatics is the premiere website for BMW 3 series owners around the world with interactive forums, a geographical enthusiast directory, photo galleries, and technical information for BMW enthusiasts.

You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!

If you have any problems with the registration process or your account login, please contact contact us.

Go Back   E46Fanatics > Tuning & Tech > DIY: Do It Yourself

DIY: Do It Yourself
Post here to share or improve your wrench turning skills! All BMW E46 DIY tips, tales, and projects discussed inside. Learn to work on your car and know the right BMW parts you will need!

Reply
 
Thread Tools Search this Thread Rating: Thread Rating: 1 votes, 5.00 average. Display Modes
Old 03-05-2007, 09:06 AM   #1
gokcer
Registered User
 
Join Date: Apr 2003
Location: Philadelphia
Posts: 2,493
My Ride: 323Ci Sports Package
Arrow Making a home made intake box from HomeDepot parts.

Parts from HomeDepot

One sheet - 24 In. x 36 In. Galvanized Steel Flat Sheet ($5-10)
http://www.homedepot.com/prel80/HDUS...4+3573&pos=n05

Single roll of insulation material(Sticky rubber on one side and aluminum on the other, the size of paper towel) HomeDepot, found Heating/Air Cond. Section

2 pieces of self adhisive foam piping insulation. They look like big foam sticks to cover pipes. $5-10 (HomeDepot, found Heating/Air Cond. Section)

1 x Metal Scissors

1 x Cardboard box to create a template

1 x K&N filter that looks like mine(2.5-3.0 inch diameter) $65 pep boys

1 x 90 degree plastic air intake bend(2.5-3 diameter Chrome color)

1 x spray paint to match your color or just black ($5 caliper paint from pepboy works great plus, dries quick, durable, heat resistant & was a perfect color match to my car) and I had it from painting my calipers


Steps
1. Remove stock intake box
2. Use a junk cardboard and draw/create a template of a heat shield. You can draw and cut the cardboard as you go along. This is the most crutial step. Make sure your card board template fits perfectly in to your intake bay around alternator, oil filter. Mark the holes for air intake tube to engine and stock air snorkel from the grille.

3. Once your cardboard template is perfect, use the metals scissors to cut the same shape from the Steel ducting sheet. Bend it to shape( recommend heavy duty gloves. Metal edges are razor sharp so it can slice your hands)

4. fold/bend all the sharp edges about 1/4 inch inwards with pliers. This elimates the sharp edges plus will make the shield more rigid. If you dont fold the edges, it will be too flimsy and wobble around. Plus edges could cut hoses and stuff.


5. Fit the metal shield in your car and make sure it is snug and everything is aligned. if all good then sit nd admire your work for 5 mins.

6. Cover the outside of the shield with your sticky foam/aluminum roll of insulation material. If you have left over, cover the inside as well. This will reduce direct heat transfer from the engine since the shield is metal.

7. Paint the shield with spray paint.( i used a 5$ red caliper paint from pep boys, it dries quickly and more durable)

8. Cover top and bottom edges of the shield with the pipe insulation foam sticks. This will make sure there is no metal to metal contact between the shield and the car body. It will also insulate the seams so heat doesnt get in.

9. I cut the 90 degree plastic bend from pepboys to a 30 degree piece and stuck that between the MAF and the K&N filter. 30degree is what I needed to fit the K&N in an angle away from the engine. Your filter might differ.

10. Connect the top stock air inlet to the hole in your shield.

11. You are done!!! Now you are a proud owner of a HomeMade intake that will perform better than most others. And you can brag about how you built it.

Total cost was less then $100 most of it being the K&N filter.

Most important area is the cardboard template. Make sure it is a good fit. It is a little trial and error to get the top of the shield so it is close to the hood. You do NOT want make it real close to the hood because top edges will be covered by insulating foam sticks which is about 1/4 inch thick. So don't try to make it a perfect fit to the hood, just put a 1/2-1/4 gap between top edge of the shield and the hood then cover the gap with the foam sticks.
__________________
Looking for a cheap Auto Insurance? Try AutoInsuranceGeek.com
If you have helpful tips about auto insurance, email me at info@townsbestsingles.com

Bright-Red 323ci 5sp. Sports + Premium + Homemade K&N intake box. --> DIY Instructions
Also for single fanatics try My 100% Free dating service - TownsBestSingles.com
New House Tool 4 in 1 Mortgage & Tax Savings Calculator for home buyers

Last edited by gokcer; 03-05-2007 at 09:14 AM.
gokcer is offline   Reply With Quote
Ads by Google

Guests, get your FREE E46Fanatics.com membership to remove this ad.
Old 03-05-2007, 01:12 PM   #2
CashFlow87
Registered User
 
Join Date: Feb 2007
Location: 714 & 562
Posts: 262
My Ride: '01 330i
Good Sh*t. im gonna do this and ill have B4, during, and after pix.

how does it sound compared to the stock box?
CashFlow87 is offline   Reply With Quote
Old 03-05-2007, 04:29 PM   #3
redbmwm3
Registered User
 
Join Date: Aug 2006
Location: New York City
Posts: 187
My Ride: 2000 323ci
I hope it dosen't snow this weekend, because I'm putting in an air system.
Sweet!
redbmwm3 is offline   Reply With Quote
Old 03-05-2007, 11:34 PM   #4
BmwPerfection
Registered User
 
BmwPerfection's Avatar
 
Join Date: Nov 2005
Location: Salt Lake city, UT
Posts: 222
My Ride: 3.5 M3 & 00 323ci
Send a message via AIM to BmwPerfection
No offense and correct me if im wrong but didn't you come up with another intake before this one? If you did I give you props for both inventions...
__________________
BmwPerfection is offline   Reply With Quote
Old 03-06-2007, 12:52 AM   #5
jiigan
Registered User
 
Join Date: Jan 2007
Location: Hollywood, CA
Posts: 201
My Ride: 05 330i ZHP
Hey that a great Diy, but do you think we can get some more pictures.
Of the metal heatshield in particular.

Thanks in advance
__________________

PowerSeller on ebay " Free2Sell_Online" - Ask about my fanatics discount! Check out my auctions.
jiigan is offline   Reply With Quote
Old 03-07-2007, 08:26 PM   #6
ROOFLESS
Registered User
 
Join Date: Feb 2006
Location: Toronto\Jupiter FL
Posts: 2,158
My Ride: has a 3.2L bag now
for later
__________________
ROOFLESS is offline   Reply With Quote
Old 03-09-2007, 01:36 AM   #7
BreakMyWallet
Registered User
 
Join Date: Oct 2005
Location: So Cal
Posts: 9,215
My Ride: B6 A4/ Mini Cooper S
looks good in your sig man.. notice any gains? sound?
__________________
BreakMyWallet is offline   Reply With Quote
Old 03-09-2007, 01:43 AM   #8
mikepbrooks
Registered User
 
Join Date: Jul 2006
Location: Florida - Panama City Beach
Posts: 641
My Ride: e46 323i
Send a message via AIM to mikepbrooks
i made one like 2 weeks ago...nice job!
__________________

You have big shoes on your car ehh? Well i wear size 13 shoes, so what do you think is big on me? Thats right my socks...and what of it!

I like long walks on the beach at sunset and picking flowers to smell them...I hope no one reads this...

Find me on MySpace and be my friend!
mikepbrooks is offline   Reply With Quote
Old 03-09-2007, 02:06 AM   #9
dtk
Registered User
 
Join Date: Oct 2006
Location: the Internets
Posts: 542
My Ride: E46
Wow. I saw the title of the thread and started humming the Sanford and Son theme song. But that looks good and professional. One question though... won't the box restrict the flow of fresh air to the intake? You might actually choke your engine.
dtk is offline   Reply With Quote
Old 03-09-2007, 08:45 AM   #10
NoVaDreier
Registered User
 
Join Date: Nov 2002
Location: Alexandria, Va.
Posts: 521
My Ride: 2001 325i
Check out his photo carefully to see the cutout in the heatshield for fresh air from the grill air intake.
NoVaDreier is offline   Reply With Quote
Old 03-09-2007, 09:21 AM   #11
dtk
Registered User
 
Join Date: Oct 2006
Location: the Internets
Posts: 542
My Ride: E46
Quote:
Originally Posted by NoVaDreier View Post
Check out his photo carefully to see the cutout in the heatshield for fresh air from the grill air intake.
Yeah, but I still think its restrictive. Let us know how the car is running.
dtk is offline   Reply With Quote
Old 03-09-2007, 11:59 AM   #12
CashFlow87
Registered User
 
Join Date: Feb 2007
Location: 714 & 562
Posts: 262
My Ride: '01 330i
Quote:
Originally Posted by dtk View Post
Yeah, but I still think its restrictive. Let us know how the car is running.
cant be much more restrictive than the stock box, dont you think? Im definatly doing this this weekend, ill take pix and let u guys know how it sounds/feels etc.
__________________

01 330i | Sport | Premium| Custom Intake & Heatshield | Smoked Clear Corners | 7% Tint All Around | 12' Kicker CVR
CashFlow87 is offline   Reply With Quote
Old 03-09-2007, 12:03 PM   #13
CashFlow87
Registered User
 
Join Date: Feb 2007
Location: 714 & 562
Posts: 262
My Ride: '01 330i
Quote:
Originally Posted by mikepbrooks View Post
i made one like 2 weeks ago...nice job!
hey u got any pix? i was thinking of even replacing the accordian tube piece also u guys think this will make a difference in sound or feel?
__________________

01 330i | Sport | Premium| Custom Intake & Heatshield | Smoked Clear Corners | 7% Tint All Around | 12' Kicker CVR
CashFlow87 is offline   Reply With Quote
Old 03-09-2007, 01:41 PM   #14
mikepbrooks
Registered User
 
Join Date: Jul 2006
Location: Florida - Panama City Beach
Posts: 641
My Ride: e46 323i
Send a message via AIM to mikepbrooks
you also have to think, below the back of the headlight is a pretty big hole...
__________________

You have big shoes on your car ehh? Well i wear size 13 shoes, so what do you think is big on me? Thats right my socks...and what of it!

I like long walks on the beach at sunset and picking flowers to smell them...I hope no one reads this...

Find me on MySpace and be my friend!
mikepbrooks is offline   Reply With Quote
Old 03-09-2007, 03:12 PM   #15
DarXide
Registered User
 
DarXide's Avatar
 
Join Date: Nov 2004
Location: MIAMI
Posts: 7,816
My Ride: Slammed on F2's
Send a message via AIM to DarXide Send a message via MSN to DarXide
Quote:
Originally Posted by dtk View Post
Yeah, but I still think its restrictive. Let us know how the car is running.
As you can see in the pic he cut a hole the same size as the OEM snout and he fitted it in there, so he is getting the same amount of Air as on the stock box..with less restriction.
__________________
FS 20'' Avus 3 piece wheels with tires 80% thread $2,000 + shipping
FS Brembo BBK 4 Piston 380mm front 345mm rear (silver) $3,800 + shipping
DarXide is offline   Reply With Quote
Old 03-09-2007, 03:13 PM   #16
DarXide
Registered User
 
DarXide's Avatar
 
Join Date: Nov 2004
Location: MIAMI
Posts: 7,816
My Ride: Slammed on F2's
Send a message via AIM to DarXide Send a message via MSN to DarXide
Quote:
Originally Posted by mikepbrooks View Post
you also have to think, below the back of the headlight is a pretty big hole...
That too
__________________
FS 20'' Avus 3 piece wheels with tires 80% thread $2,000 + shipping
FS Brembo BBK 4 Piston 380mm front 345mm rear (silver) $3,800 + shipping
DarXide is offline   Reply With Quote
Old 03-09-2007, 04:58 PM   #17
gokcer
Registered User
 
Join Date: Apr 2003
Location: Philadelphia
Posts: 2,493
My Ride: 323Ci Sports Package
Oh jeez, I didnt think people would respond to it this much.

Box is not restrictive at all. It feeds fresh air from the stock air snorkle on top + it gets fresh air via brake duct using 3inch dia hose from bottom.

You dont really need the hose but I put it in anyway. Heat shield is open at the bottom so it gets fresh air from the brake ducts.

I had this one on my car close to a year I think and no problems what so ever. It sounds like a monster at full throttle. I cant really say I see alot of power gains. It would work better if I had a software upgrade.

Car is at 172K miles and last 70k+ was with my homemade intakes.

This is my 3rd one. I made another one from thin plywood which had the top portion closed as well but it muted the sound so I came up with this one.

This one looks like a stock part, color match is almost exact. It sounds good, it looks good, it performs same or tiny bit better than stock so I give my self 2 thumbs up.


Here is side picture that was after a lot of driving


__________________
Looking for a cheap Auto Insurance? Try AutoInsuranceGeek.com
If you have helpful tips about auto insurance, email me at info@townsbestsingles.com

Bright-Red 323ci 5sp. Sports + Premium + Homemade K&N intake box. --> DIY Instructions
Also for single fanatics try My 100% Free dating service - TownsBestSingles.com
New House Tool 4 in 1 Mortgage & Tax Savings Calculator for home buyers

Last edited by gokcer; 03-09-2007 at 05:10 PM.
gokcer is offline   Reply With Quote
Old 03-09-2007, 07:39 PM   #18
EDawg
Registered User
 
Join Date: Jan 2004
Location: CA
Posts: 4,773
My Ride: :/
wow. that looks really good for homemade. not a big fan of the red paint on the heat shield though.
EDawg is offline   Reply With Quote
Old 03-09-2007, 10:17 PM   #19
gokcer
Registered User
 
Join Date: Apr 2003
Location: Philadelphia
Posts: 2,493
My Ride: 323Ci Sports Package
Though about black but I had left over red caliper paint so that what I used.
__________________
Looking for a cheap Auto Insurance? Try AutoInsuranceGeek.com
If you have helpful tips about auto insurance, email me at info@townsbestsingles.com

Bright-Red 323ci 5sp. Sports + Premium + Homemade K&N intake box. --> DIY Instructions
Also for single fanatics try My 100% Free dating service - TownsBestSingles.com
New House Tool 4 in 1 Mortgage & Tax Savings Calculator for home buyers
gokcer is offline   Reply With Quote
Old 03-09-2007, 11:24 PM   #20
dtk
Registered User
 
Join Date: Oct 2006
Location: the Internets
Posts: 542
My Ride: E46
That really does look good. I see your plan better in the other photos. Do you think the box itself adds to the sound of the aftermarket intake?
dtk is offline   Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Censor is ON





All times are GMT -5. The time now is 01:49 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
(c) 1999 - 2011 performanceIX Inc - privacy policy - terms of use