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Anderzander

Member Since: 08 Feb 2011
Location: Lancashire
Posts: 1000

Anyone measured how long the pipe is from airbox to wing ?

The big diameter ones look to need to be longer.

25th Apr 2015 6:41pm

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

2004 Defender 110 Td5 DCPU Stornoway Grey

Right, got some pics together with a bit of explanation below them.

All tubes are from ASH (Auto Silicone Hoses).

Click image to enlarge

This is the wing intake. It's an alloy curved 102mm trumpet. I did order one with a flat face, but they sent a curved so I had to deal with it. The trumpet does in fact cover a range of sizes, so I cut it to suit and make it a nice tight fit without any excess sat inside the tube. There were more cable ties holding it in, but when the cage went on, it had to be removed and it's not yet been put back properly!

I will be sourcing a flat one and creating a whole plate to cover the wing hole. Should of been black to but got sent silver!

Click image to enlarge

From there it fits into the 102mm 2-Ply tubing which creates it own 90 bend. I will be changing this to a silicone 90 bend, cut down to suit. A fresh cutting blade can create a very clean and sharp cut in a silicone tube. Easy to modify. Jubilee clip makes a good cutting form.

Click image to enlarge

The tube the runs up the wing, around the wing brace, then tucks between the brake master cylinder and the intake manifold.

Click image to enlarge

The 102mm tubing then runs into a 102mm alloy tube joiner, then into a 102mm to 90mm reducer.

Click image to enlarge

This the runs into the standard intake tube which clips into the airbox. I have modified this and cut it right back to leave just enough stub to latch the reducer tube onto. The O.D of the standard plastic piece is 90.8mm by my verniers.

Click image to enlarge

Quick shot of it into the airbox.

-----

Click image to enlarge

This is a 70mm to 60mm reducer which is again cut to match the OEM tube, including the cut out. Again, a fresh blade makes this a nice easy task to make a nice clean cut. There's a 19mm Revotec self sealing tube adaptor to for the crank breather. I now have this blanked off and the catch can breathing to atmosphere. As seen below.

Click image to enlarge

Click image to enlarge

This is an 80mm turbo bellow coupler. Shortened with the little notch sections cut out to!

26th Apr 2015 8:23pm

Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

Thanks for taking the pictures Taaz, much appreciated and of great help, that makes things much clearer.

I'm going to be ordering some pipe etc today from ASH, I'm just trying to work out if it's worth going for 102mm hose or if 76mm will suffice, mines in a mild tune of about 160-170 bhp, with larger intercooler, removed egr, performance exhaust etc, the smaller pipe would make it easier for routing as it'd follow the original path but without all the kinks and joins, and it'd join the original 'trumpet' intake on the airbox without cutting it, but now I've seen yours I might go for the larger pipe.
I'm thinking of getting one of these and cutting/ joining it to the wing air intake to finish it off....
http://pages.ebay.com/link/?nav=item.view&...1125011106

Once again, thanks, what a great forum, with great members

27th Apr 2015 7:55am

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

76mm will improve things! Like you say, will be easier to route to.

This was the trumpet that I had ordered but didnt show:

Revotec 102mm Flat (actually called an outlet):

Then I was going to make a 1mm SS plate behind it and sandwich it into the standard wing intake. Then IMO a 90 degree silicone bend would make life easier to at the wing with a joiner into the tube.

Initially just whilst you play, it might be cheaper to get some of the cheap tubing, then do a test route and in the future go for the more expensive, higher ply, smoother stuff.

27th Apr 2015 8:07am

Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

cheers again
I was going to use the original side vent (the inner plastic part that you must have removed, that the outer vent gets pushed into) and cut a hole in it, then connect the 76mm plate to that, and seal it up, that would then still allow any water or drips to exit through the bottom, which was the original air inlet (if that makes sense). I'd have to come up with some idea of a gauze cover or something that would stop crud from getting in from splashes, that's still work in progress

27th Apr 2015 8:24am

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

I've never had any issues with water etc ...

I do have to change the air filter quite frequently as it clogs up much much quicker, but that's bound to happen.

You might struggle to use the standard oem wing piece (the square piece with the big oval tube joint?). With that in place it vastly reduces the space you have before hitting the clutch pedal box. Though I've never used 76mm so may be easier to work with

27th Apr 2015 8:46am

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

Your welcome to mine if you like as I dont plan on needing it again in the future. Like I say, I'm changing mine again at some point and probably wont use the wing intake at all.

Good as a backup. I had 3 air boxes whilst I played about getting that tube to fit somehow. I used all 3 before being happy with where I was at

27th Apr 2015 8:49am

Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

thanks, I'll bear that in mind, if I get it wrong when cutting I'll no doubt take you up on that

On another note - I notice you have a Provent - does it collect much, would you recommend fitting one?

27th Apr 2015 9:31am

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

The ProVent is a recent addition.

Before that I had an Allard Alloy Catch can which is a nicely made unit, but wasn't right for me.

Mine breathes rather heavily, so not sure if this would the same as yours, but every couple weeks I drain out a reasonable splodge! I've never measured, but maybe 50ml ... 100ml maybe? Though at the moment the filter itself is about half 'oiled up', so that's still catching some. Once the filter is full it'll be interesting to see how much gets forced through!

I think my crank pressure is a little high, possibly down to the VNT, but also I think there's something else a miss, but I shant worry until it's more of a problem! Need to get the Pico on it and do a relative compression test. Just never seem to get around to it (Probably dont want to know subconsciously).

27th Apr 2015 9:55am

K9F

Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610

2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey

Lambley I have a Provent 200 fitted to my Puma. Whilst the amount it collects is evident it is not a significant amount. It is more to prevent the oil mist from carboning up your turbo and intercooler.
It really is down to personal choice but I naturally thought the modification worth doing as did several others. Beware though if you do look for one, there are many copies about. Go genuine. I'll see if I can find the link and add it.

**EDIT**

ibexman wrote:
Trying to find a genuine Provent 200 in the uk is a bit like finding the holy grail.
After searching the net i took a look on VAG VW AUDI forums they have some very nice provent installs,which led me to a uk trade supplier POWER UTILITIES GROUP ON 01922 720461 press option 1 filtration and and ask for Matt Nicholls , I asked him if he would sell me a provent 200 he was more than happy to help £75+vat+£16.50 carraige it worked out to around £109 cheaper than a fake from darkside for £117 and uk filters at£150 hope this helps cheers Chris

Taazzukcb have you blanked off the drain feed or fed it back as a return oil feed? I have heard if you return the oil drain you can set up a syphoning effect. I haven't had 50ml drain off in total, just a misting really. Sorry for the off topic.

If you go through life with your head in the sand....all people will see is an ar5e!!

Treat every day as if it is your last....one day you will be right!!

27th Apr 2015 9:57am

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

The outlet to what would be the Turbo hose is vented to atmosphere now and the drain outlet on the bottom I have fed down to the outrigger with a Tap on it, so it collects in the tube and I can open the tap and let the build up out.

The problem with the syphoning as far as I was aware, was that people were mounting the drain to high. Above the sump level. Some used to solder into the turbo oil drain.

But it's supposed to go below the oil level in the sump, otherwise it can cause problems.

But the ProVent has only been on a month or 2 and like I say, since fitted its been vented to atmosphere, and drain off pipe down to the outrigger and I'm dropping probably closer to 50ml every couple weeks.

27th Apr 2015 10:13am

K9F

Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610

Thanks, it still seems quite a lot at 50ml but I suppose it depends on the mileage and how hard the engine is worked perhaps? If you go through life with your head in the sand....all people will see is an ar5e!!

Treat every day as if it is your last....one day you will be right!!

27th Apr 2015 11:24am

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

Just clocked 104,000.

But before my purchasing of it, it was used to pull logging trailers through forests so probably hasn't has the easiest of life and I suspect idling a lot, so maybe a little glazed!

Then myself, I've not got the lightest foot. I tend to sit at 60-65, but I do like to get there quick

. But I dont tow, and 80% is on road.

It's been shoving a reasonably splodge out now for a couple months. VNT etc all went on Nov/Dec and only really noticed the heavy breathing around the end of Feb as the clear pipe was clear, but then noticed it starting to get quite oily!

Seems pokey enough mind. Like I say, I shant panic to much!

27th Apr 2015 1:04pm

K9F

Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610

It's obviously doing exactly what it was designed to do. As for the induction modification excellent write up. Almost makes me wish I had a TD5 to follow the instructions.

If you go through life with your head in the sand....all people will see is an ar5e!!

Treat every day as if it is your last....one day you will be right!!

27th Apr 2015 3:05pm

ibexman

Member Since: 13 Dec 2008
Location: Essex
Posts: 2945

Where does your provent outlet finish up

27th Apr 2015 4:33pm

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