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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
Air Intake Mod
Hi all!

Having looked through some old posts on the forum, I'm keen to improve my air intake system. I'm trying to find someone who makes/can make an inlet/duct to replace to wing mounted plastic unit. This would be so I can fit a piece of 102mm ducting between the wing and airbox - on a Td5.

Does anyone know who makes an inlet like this? I think IRB and BAS used to make them but there's no sign on BAS' website that they still make them and IRB aren't so easy to get hold of. I have asked a couple of fabricators if they could do it but I've only had a response from one who has since gone quiet.

Any ideas would be great, thanks! Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #788469 24th Aug 2019 12:04pm
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Pilgrimmick



Member Since: 16 Nov 2015
Location: Highlands
Posts: 582

United Kingdom 
Is it for fresh air, or to protect against water?

Require a different approach for different tasks. 80" 1948
Lightweight V8
Bowler Tomcat
130 Station wagon
90 300tdi
(Santana PS10 pick up)
Range Rover L322 (Ful fat)
Post #788471 24th Aug 2019 12:35pm
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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
For fresh air. It's just to increase the volume of air reaching the airbox and to reduce the restriction created by the factory setup. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #788474 24th Aug 2019 12:51pm
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Bluest



Member Since: 23 Apr 2016
Location: Lancashire
Posts: 4210

United Kingdom 2007 Defender 110 Puma 2.4 XS CSW Java Black
There’s the Nugget Stuff kit sold by First Four in the UK, or I think Nakatanenga do a kit 5he re routes the intake to the wing top to match their snorkel. 2007 110 TDCi Station Wagon XS
Post #788475 24th Aug 2019 1:03pm
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Pilgrimmick



Member Since: 16 Nov 2015
Location: Highlands
Posts: 582

United Kingdom 
For best flow then you need to reduce any bends or elbows in the pipe. Any joints will also reduce the laminar flow through the pipe. The Southdown type snorkel that went through the wingtop was excellent in this regard, reducing bends and joints. From the top of the pipe to inside the engine bay was a straight pipe, then there was a single flexi hose to the air filter.

The air filter itself is a major choke point on most systems, improved flow filters will make a significant improvement, look at changing the filter to improve air flow, before looking outside the engine bay. There was an excellent thread on fitting larger air filter units to tdi engines , but for some reason the search engine seems not to work on my iPad, so cannot find it. 80" 1948
Lightweight V8
Bowler Tomcat
130 Station wagon
90 300tdi
(Santana PS10 pick up)
Range Rover L322 (Ful fat)
Post #788478 24th Aug 2019 2:12pm
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Joe the Plumber



Member Since: 18 Dec 2013
Location: Midlands
Posts: 907

2014 Defender 110 Puma 2.2 HT Fuji White
If I may, I'll remind you that Pete Bell did a comprehensive test on aftermarket and standard air filter elements (sadly now no longer available on here) and if you want maximum power, the standard air filters win every time.
Post #788485 24th Aug 2019 3:54pm
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2169

2004 Defender 110 Td5 DCPU Epsom Green
If you have ABS there isnt enough space to run a 4" hose biggest I could fit was 3"

Heres my set up.


3.5" snorkel leading to a 4" hose direct to the air box. Airbox has been whittled out for maximum air flow.



Click image to enlarge




Click image to enlarge




Click image to enlarge
 Instagram @defender_ventures
Empire Tuning - Agent
Post #788492 24th Aug 2019 5:55pm
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derbywill



Member Since: 25 Mar 2010
Location: Derbyshire
Posts: 559

England 2005 Defender 90 Td5 XS CSW Java Black
I have a Td5 with ABS and I managed to get 80mm ducting in. I have a snorkel and welded an aluminium elbow into a flat piece of aluminium to mount to the wing where the original intake is. I need to make a better connection to the filter box to help seal it better.

Cheers

Will 2005 90 XS
1954 86'' Series 1 tilt
1968 88” 2A 200tdi
2002 110 Hardtop
Post #788495 24th Aug 2019 6:46pm
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

United Kingdom 
Hey Bankz what did you do at the airbag end?
Post #788594 25th Aug 2019 7:06pm
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2169

2004 Defender 110 Td5 DCPU Epsom Green
Airbox end, cut the original pipe work down until it was the same diameter as the hose then jubilee clip + RTV Instagram @defender_ventures
Empire Tuning - Agent
Post #788607 25th Aug 2019 8:09pm
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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
That’s the kind of thing I’m looking for Bankz, but retaining the original air inlet on the side of the wing. No ABS so there’s plenty of space Thumbs Up Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #788628 26th Aug 2019 6:36am
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

United Kingdom 
bankz5152 wrote:
Airbox end, cut the original pipe work down until it was the same diameter as the hose then jubilee clip + RTV


As simple as that. Thumbs Up Thumbs Up
Post #788634 26th Aug 2019 7:43am
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Bluericky



Member Since: 26 Jun 2014
Location: Cornwall
Posts: 647

United Kingdom 2009 Defender 110 Puma 2.4 DCPU Keswick Green
A truly worthwhile modification, I fitted the nugget kit , purchased off a forum member . The turbo is quicker to react , the engine sounds far happier and the note is ever so slightly ‘ throatier ‘. It may be my imagination but it feels far more responsive as a result . I left the standard air filter housing and filter in place .

Got to admit though , you could do a DIY job for a sliver of the price that the nugget kit cost ! https://www.instagram.com/hustynminepark/
Post #788671 26th Aug 2019 12:19pm
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2010Blackdefender90



Member Since: 07 Jan 2018
Location: London
Posts: 562

United Kingdom 2011 Defender 90 Puma 2.4 SVX Station Wagon Santorini Black
Nugget stuff kit is the way to go, continuous pipe to the air box. Also look at their replacement sealed air box. I have one and, although I have RAI, feels more responsive and sounds raw exhaust sound when pushed. Puma airboxes are useless.
Post #788674 26th Aug 2019 12:31pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17391

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
The Nugget replacement filter with a proper large bore intake (Nugget, Nakatanenga, or similar) makes a verh marked difference. I thing the Nugget filter is TDCi only though.


Click image to enlarge
Post #788684 26th Aug 2019 2:07pm
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