 | Home > Maintenance & Modifications > Air box mod and decat |
 
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I said "something like" that - Ian at Dixon Fabrication will do lots better for less, including powdercoating them (as well as not welding crap-ly like the pic 
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| LandieG Member Since: 13 Mar 2013 Location: nr Caerphilly Posts: 91  |
As they don't need to be metal, was also exploring a 3D printed one, but that wasn't as good value when I asked about…!
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16th Mar 2016 10:19pm |
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| Supacat Member Since: 16 Oct 2012 Location: West Yorkshire Posts: 11018  
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I didn't realise that the part only clipped in - I thought others had mentioned cutting it out. Mine has this printed on the airbox and I wondered if it referred to this part and there were actually two different versions of the airbox:  Click image to enlarge |
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17th Mar 2016 11:35am |
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| andre.prum Member Since: 24 Feb 2014 Location: Bridel Posts: 8  
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Hi,
After doing the air box modification, I have also changed the air intake from the Mantec snorkel into the airbox by replacing simple the OEM circuit by a large PVC tube with a smooth inner side sealed directly into the airbox. The engine runs very smoothly now with Pete's BAS remap offering plenty of power and torque.
With the rainy days coming up, I just wonder if during a all day long ride for instance on a rainy autoroute, in getting rid of the water separator in the airbox I do not run the risk that the filter gets wet and ultimately could be destroyed with pieces suck into the engine. I have left the water hole in the airbox so that some water could still evacuate. The head of the Mantec snorkel induces an air turbulence that could already avoid some of the water to get into the air intake. I would very much appreciate your views on 1) if the Mantec snorkel head sufficiently avoids mist and rain water to reach the air filter ? 2) What type of cyclonic pre filter could help to reduce even further the risk. I have just bought a Donaldson Topspin H002425 refilter offering an operating flow ange of 200-450 CFM (5.7-12.7 m3/min). But the large plastic bowl is not really made for off-road use as I am afraid that a ride in the forest would easily destroy the pre filter. Donaldson is making a HD version of the Topspin filter. The model with the correct outlet (H002852) has an operating range of 150-275 CFM (4.2-7.8 m3/min). Below is a chart on the level of restriction of this filter.
My question are : a) what airflow does the the PUMA 2.4 defender engine with the Bas remap require to work fine? b) would the level of restriction of the Donaldson HD Topspin pre filter H002852 hamper the engine from developing comfortable power and torque? c) is there any better alternative ? many thanks in advance for your views in this |
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23rd Aug 2016 8:22am |
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| Yannis Member Since: 02 Feb 2015 Location: Oxfordshire / Milan Posts: 408 
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Ciao,
I have done the air box mod; Click image to enlarge I have also made a new wing vent adapter for my nice big bore intake pipe; Click image to enlarge Click image to enlarge Click image to enlarge Now, I have just been for a 45 minute drive in the pouring rain (puddle hopping) and thought I would check the air filter when I got back. One corner of it is soaked...... The filter vanes are dry but the stuff that looks like white scouring pad was drenched in one corner. The top of the filter was also bone dry, so I'm not worried about water getting into the engine, I'm just wondering how wet would the air filter be with a standard air intake setup...? Thoughts appreciated Yan |
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5th Nov 2017 3:52pm |
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| familymad Member Since: 13 Dec 2011 Location: Bucks Posts: 3481  
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Too dry to comment right now 1951 80" S1 2.0
1995 110 300TDI 1995 90 300TDI |
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5th Nov 2017 5:21pm |
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| familymad Member Since: 13 Dec 2011 Location: Bucks Posts: 3481
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Anyone else had a wet air filter only after the mod? 1951 80" S1 2.0
1995 110 300TDI 1995 90 300TDI |
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26th Dec 2017 2:04pm |
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| williamthedog Member Since: 29 Dec 2012 Location: south wales Posts: 3441 
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Mines been fine for years, no water ingress at all
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26th Dec 2017 8:41pm |
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| familymad Member Since: 13 Dec 2011 Location: Bucks Posts: 3481
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Right, modding the intake today and fitting a Naka intake kit. Will report back. 1951 80" S1 2.0
1995 110 300TDI 1995 90 300TDI |
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6th Jan 2018 8:09am |
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| lohr500 Member Since: 14 Sep 2014 Location: Skipton Posts: 1316 
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Been outside this morning and performed surgery on mine.
I left the airbox in place to do the work as I didn't fancy extracting the whole thing. If it helps, here's a bit of a walk through for anyone else thinking about doing the mod.
Stuff a rag into the clean air hose to stop any c**p getting where it shouldn't. Make sure nobody starts the engine with the rag in place 
Release the two clips which secure the airbox lid to the main body then remove the lid from the base. It hinges upwards from the clip end and then slides out from under the wing. If you have air con fitted, jiggle it around the air con pipe running from the compressor. Remove the air filter. From inside the airbox, cut away the tubular moulded section so you end up with the airbox looking like the pictures shown in earlier posts from custom90steve & Yannis. I did the rough work with a pair of side cutters and a cordless Dremel using a metal circular cutting saw, then a hot knife tip on a gas powered soldering iron to tidy up and smooth any jagged edges. Remove the fixed fan assembly. I did this by cutting through the blades with side cutters as much as I could, then grabbing bits of the fan with a pair of mole grips and twisting them out. After extracting a few blades, the whole centre section then twisted out. That just left the outer ring which was easy to pry out using a screwdriver. Vacuum away any plastic swarf and other pieces from the surgery, making sure the two drain holes in the base of the airbox are not clogged up. Make sure no bits of the fan are left in the dirty air inlet pipe to the airbox. The filter should catch anything that has been missed, but better to clean it out thoroughly than tempt fate. Refit the air filter and airbox lid. Remove rag from clean air hose, reconnect to air box lid and refit the air flow sensor connector plug. Less than 30 minutes and job done. Including a trip to the 1st aid cupboard for a plaster to stem the flow of blood from a finger that was sliced open by a particularly sharp shard of plastic on a piece of the fan   At least I have added another layer of security by forensically marking part of the airbox with my own blood which I guess is almost as good as Smartwater.
I'll be going for a run in the Defender shortly and will report back. Update after a quick run out : Hard to say what improvement there is really, as I am still smiling from ear to ear with the BAS 150 remap I loaded before Xmas. It may be wishful thinking but it seems to accelerate a little harder than before, pulling well in 3rd & 4th from lower RPM. |
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6th Jan 2018 3:51pm |
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| Dean the BR12KY Member Since: 03 Aug 2017 Location: perth Posts: 3  
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I just carried out this mod, only took 30 minutes to do, I used a hack saw blade to cut out the plastic air inlet part inside of the box, was really easy, was tricky removing the propeller fan, but was made easyer by loosening the dirty air pipe mount on the wheel arch to allow the pipe to be pulled out from the box
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19th May 2018 7:31pm |
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| tx1836 Member Since: 04 Oct 2018 Location: Cologne Posts: 1  
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Hi, just one question....I was thinking about ...
when you mod the air intake from snorkel to air box, bigger diameter, has anyone tried to attache direcly to the wing cold air intake, square black plastic box , instead of using an adapter...? Thanks Tom |
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20th Feb 2019 2:17pm |
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| Yesjus Member Since: 19 Sep 2022 Location: Surrey Posts: 78
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Looking at doing this mod this weekend and was looking for pointers…your pics don’t seem to be on the server anymore? Could you upload again by any chance? Thanks |
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12th Jan 2023 11:16pm |
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| Yesjus Member Since: 19 Sep 2022 Location: Surrey Posts: 78
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Looking at doing this mod this weekend and was looking for pointers…your pics don’t seem to be on the server anymore? Could you upload again by any chance? Thanks |
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12th Jan 2023 11:16pm |
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| Yesjus Member Since: 19 Sep 2022 Location: Surrey Posts: 78
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Looking at doing this mod this weekend and was looking for pointers…your pics don’t seem to be on the server anymore? Could you upload again by any chance? Thanks |
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12th Jan 2023 11:16pm |
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