TJ "Hummer" cold air intake - Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > General Jeep Discussions > Builders Corner

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 05-15-2012, 10:23 PM   #1
Jeeper
 
wml52's Avatar
 
Join Date: May 2012
Location: Upstate NY
Posts: 21
TJ "Hummer" cold air intake

OK so here is my variation on the HUMVEE cold air intake theme. Now I just want to state that this mod was not an effort to fabricate a snorkel, but rather a way to get cooler air into the intake, although I suppose you could use it as a snorkel if you extended the intake tube. However I’ve been wheeling for many years and have never had to cross water so deep that I had to use a snorkel.

Most of the credit should go to Frank Steven Taldone a.k.a. “Kerndone” he has an excellent write up on this mod posted on JeepForum.Com Write-up for a Hummer cold air intake - JeepForum.com.

The major differences between Franks mod and mine was the use of the Spectra Performance intake kit p/n 9943 instead of the Buick air box and the way I chose to modify the HVAC intake cover underneath the cowl.

The reason I used the Spectra Performance kit was that I got a really good deal on it ($50.00) otherwise the Buick air box would work just fine. I also chose to modify the existing HVAC intake cover a little differently and chose to fabricate a custom intake duct instead of the method used in the write-up. The reason for this was, in looking at the photos of the HVAC intake cover he had to cut away and cover a large portion of the HVAC intake area to allow for the fitment of the 3” diameter hose that connects to the toilet flange. I thought this would significantly reduce the amount of air (cfm) flowing through the HVAC intake adversely affecting the HVAC system.

In order to minimize the HVAC intake restriction and maximizing cfm flow rate to the cold air intake I took a few clearance measurements and made a cardboard template of the duct I wanted to fabricate. Since the Spectra intake was based on a 3” diameter tube that equates to approximately 7.0 square inches. I based my template on a duct that would give me approximately 7 square inches, which worked out to be a duct 5”x 1.5” or as close to those dimensions that available space would allow. As Frank stated it’s a very tight fit! It took a little bit of tweaking to get all the dimensions right for a proper fit and as you can see in the photo it’s not a perfect 5” x 1.5” but the shape and size does not seem to affect the cfm flow all that much.





The intake duct was fabricated from 16ga steel that I had lying around my garage, one 4.5” and one 3” exhaust pipe that I picked up at a local supplier, I also welded in place six 10-24 screws so I could mount the duct to the underside of the cowling. Once I welded all the seams I had limited access to the interior of the duct so I used Eastwood’s Internal Frame coating (p/n: 12511Z) to coat the interior of the duct to prevent any rust from forming on the inside. The outside was primed and painted using Eastwood’s Extreme Chassis Black Satin (p/n: 11175Z)
As you can see in the photos I also had to modify the HVAC cover to allow clearance for the intake duct to sit just above it and minimize flow restriction into the HVAC intake, it was just a matter of cutting away some portions of the plastic cover and laying on some fiberglass to the shape I wanted. It’s a close fit but it works quite well.

The intake duct is held in place using the six 10-24 screws and some #10 flat washers and #10 acorn nuts. The HUMVEE cap is held in place using three #10 security screws. I opted for the security screws to prevent anyone from tying to borrow the cap. Once everything was mounted in place it was just a matter of attaching the 3” tube from the intake duct to the 3” mounting flange that comes with the Spectra Performance kit, replacing the cowling and buttoning everything up.






All in all it took several hours over a couple of weekends to fabricate, fit and mount everything but I think it was well worth the effort. Your comments are welcomed.












Fabricated intake duct





wml52 is offline   Quote
Old 05-16-2012, 09:21 PM   #2
Jeeper
 
sparkyjeep's Avatar
 
Join Date: Jun 2010
Location: Fort Wayne, IN
Posts: 216
where did you get your cap at?
i have a cap off of deuce and a half.. i like the hummer cap better...

sparkyjeep is offline   Quote
Old 05-19-2012, 09:57 PM   #3
Jeeper
 
wml52's Avatar
 
Join Date: May 2012
Location: Upstate NY
Posts: 21
I bought the cap on Ebay a while back for something like $25.00. You can search some military surplus sites as well but they are a little more expensive.

Good luck in your search

Bill
wml52 is offline   Quote
Old 05-19-2012, 10:28 PM   #4
Jeeper
 
InvertChaos's Avatar
 
Join Date: Sep 2010
Location: NoVa
Posts: 8,174
Looks awesome! I edited your pictures for you so they'll actually show up in the post as pictures instead of links.
__________________
|2004 Jeep TJ "Green Machine"|4.0L 5 speed Dana44|33x12.50x15 Goodyear Duratracs|2.5" OME HD coils + 1.25" body lift|OME NitroSport shocks|4.56 gears|Skid Row Engine Skid|BCC Sliders|Currie AntiRock|
InvertChaos is offline   Quote
Old 06-07-2012, 10:06 PM   #5
Jeeper
 
wml52's Avatar
 
Join Date: May 2012
Location: Upstate NY
Posts: 21
I appreciate the edit, I'm better with a grinder then I am with the computer. One of these days I'll figure out how to insert the photos instead of the links...lol
wml52 is offline   Quote
Old 08-15-2012, 05:27 PM   #6
Newb
 
ddecker2010's Avatar
 
Join Date: Aug 2012
Posts: 1
that's awesome man! i'm wanting to do the same. if you don't mind me asking, what are the dimensions of that sheet metal piece that goes in the cowl?
ddecker2010 is offline   Quote
Old 09-02-2012, 06:13 PM   #7
Jeeper
 
stykthyn's Avatar
 
Join Date: Mar 2011
Location: gainesville florida
Posts: 1,238
I need to make one of those
__________________
1995 YJ- daily driver
1987 Mustang- the money pit. " I wanna go fast!"
stykthyn is offline   Quote
Old 09-07-2012, 10:20 AM   #8
Jeeper
 
Join Date: Jul 2012
Posts: 203
This is very cool. Very nicely done.
markmdz is offline   Quote
Old 09-22-2012, 11:12 PM   #9
Newb
 
Join Date: Apr 2012
Posts: 14
Won't the tubing get fairly hot since it goes right over the motor?
RSellers is offline   Quote
Old 09-22-2012, 11:14 PM   #10
Newb
 
Join Date: Apr 2012
Posts: 14
By the way what is the black thing on the hood in the first picture?
RSellers is offline   Quote
Old 01-03-2013, 02:37 PM   #11
Jeeper
 
obidya's Avatar
 
Join Date: Sep 2011
Location: Fort Wayne, Indiana
Posts: 1,544
thats petty cool actually... (didnt think I was going to like it)

I would make the up spout removable so you can still drop the windshield.
__________________
Black 97 Sahara 4.0L 5 Speed - Fully Cloak'd
1.5" BL with 35"x12.5" Wrangler MTR w/ Kevlar 10k Engo winch
obidya is offline   Quote
Old 01-04-2013, 07:45 AM   #12
Jeeper
 
TFBlackout05's Avatar
 
Join Date: Jun 2011
Location: Coweta
Posts: 202
Looks good! How's it look under the hood?
__________________
LIVE EVERDAY LIKE IT'S YOUR LAST!
TFBlackout05 is offline   Quote
Old 01-05-2013, 07:54 AM   #13
Jeeper
 
bfschor's Avatar
 
Join Date: Sep 2012
Posts: 385
That's awesome!!! When do you put it into production??? :-)
bfschor is offline   Quote
Old 01-05-2013, 04:34 PM   #14
Jeeper
 
wml52's Avatar
 
Join Date: May 2012
Location: Upstate NY
Posts: 21
My apologies for the late response but for some reason the email notification was put into my spam folder so I didn't notice any posts until today.

To answer RSellers question about the black thing in the first photo that is the air intake for the HVAC that was modified to allow fitment of the 3" tubing that connects the HUMVEE cap to the intake manifold.

With regard to the question as to what it looks like under the hood this is what it looks like

wml52 is offline   Quote
Old 01-08-2013, 11:43 AM   #15
Registered User
 
NalinMFG's Avatar
 
Join Date: Nov 2006
Location: Evansville, IN
Posts: 973
Send a message via AIM to NalinMFG Send a message via MSN to NalinMFG Send a message via Yahoo to NalinMFG
Quote:
Originally Posted by wml52 View Post
My apologies for the late response but for some reason the email notification was put into my spam folder so I didn't notice any posts until today.

To answer RSellers question about the black thing in the first photo that is the air intake for the HVAC that was modified to allow fitment of the 3" tubing that connects the HUMVEE cap to the intake manifold.

With regard to the question as to what it looks like under the hood this is what it looks like

__________________
.com
NalinMFG is offline   Quote
Old 01-09-2013, 08:14 PM   #16
Jeeper
 
Join Date: Sep 2011
Posts: 131
real nice
__________________
I am parting out my 2003 wrangler TJ. PM for details...
Robertlena2 is offline   Quote
Old 01-20-2013, 11:04 PM   #17
Jeeper
 
danatkins's Avatar
 
Join Date: Mar 2012
Posts: 71
i've thought of the same thing i love it.
danatkins is offline   Quote
Old 01-21-2013, 06:29 AM   #18
Jeeper
 
Join Date: Dec 2011
Posts: 1,459
I did something similar, but in fiberglass so I didn't have to cut a hole in my factory cowl panel. (So I can go back to the stock cowl panel if I ever want to)





Below: the stock cowl panel compared to the custom cowl panel:



It's got a similar duct on the underside, also made in fiberglass, this shot was taken on the test tub section in my workshop...

jscherb is online now   Quote
Old 01-21-2013, 02:24 PM   #19
Jeeper
 
wml52's Avatar
 
Join Date: May 2012
Location: Upstate NY
Posts: 21
Really nice clean work, great job!!!
wml52 is offline   Quote
Old 01-22-2013, 10:17 AM   #20
PROTEK SERVICES

5-Year WF Supporting Member
 
ProTek's Avatar
 
Join Date: Oct 2011
Location: Clifton Park, NY
Posts: 374
I like how it is low profile...pretty sleek.
__________________
CLICK HERE to send me a PM.

CLICK HERE for Powder Coating & Custom Tube Bending
ProTek is offline   Quote
Old 01-22-2013, 10:41 AM   #21
Jeeper
 
obidya's Avatar
 
Join Date: Sep 2011
Location: Fort Wayne, Indiana
Posts: 1,544
Quote:
Originally Posted by jscherb View Post
I did something similar, but in fiberglass so I didn't have to cut a hole in my factory cowl panel. (So I can go back to the stock cowl panel if I ever want to)





Below: the stock cowl panel compared to the custom cowl panel:



It's got a similar duct on the underside, also made in fiberglass, this shot was taken on the test tub section in my workshop...

if you pull the filter off is there still enough clearance to drop the windshield (I'm one of THOSE types)
__________________
Black 97 Sahara 4.0L 5 Speed - Fully Cloak'd
1.5" BL with 35"x12.5" Wrangler MTR w/ Kevlar 10k Engo winch
obidya is offline   Quote
Old 01-22-2013, 11:03 AM   #22
Jeeper
 
Join Date: Dec 2011
Posts: 1,459
Quote:
Originally Posted by obidya View Post
if you pull the filter off is there still enough clearance to drop the windshield (I'm one of THOSE types)
Yes.
jscherb is online now   Quote
Old 12-04-2013, 01:53 PM   #23
Newb
 
Join Date: Oct 2013
Location: Waterbury, VT
Posts: 9
Quote:
Originally Posted by jscherb View Post
Yes.


All your work is top notch jscherb! Next time my wife drags me to Elmira for a college reunion I would love to see some of this stuff in person. Maybe I can trade you cleaning your shop for a tour?
adkfinn is offline   Quote
Old 12-04-2013, 06:37 PM   #24
Jeeper
 
Join Date: Dec 2011
Posts: 1,459
Quote:
Originally Posted by adkfinn View Post


All your work is top notch jscherb! Next time my wife drags me to Elmira for a college reunion I would love to see some of this stuff in person. Maybe I can trade you cleaning your shop for a tour?
Thank you. That would be Elmira College? My workshop is about 1 mile from the college. Not too much to see though, I do all my work in my basement workshop or garage. There are a lot of prototype fiberglass parts around though, I guess I could tour you around them .
jscherb is online now   Quote
Old 12-05-2013, 02:25 PM   #25
Newb
 
Join Date: Oct 2013
Location: Waterbury, VT
Posts: 9
Quote:
Originally Posted by jscherb View Post
Thank you. That would be Elmira College? My workshop is about 1 mile from the college. Not too much to see though, I do all my work in my basement workshop or garage. There are a lot of prototype fiberglass parts around though, I guess I could tour you around them .
Trust me, what you call your basement & garage look like a skunkworks lab compared to my "work space" everyone else refers to as my dirt driveway. Elmira College indeed, I had the pleasure of spending a weekend with those loonies a couple of years ago. I immediately began negotiations to get a pass for the next one. I still think it'd be great to see all your work in person. I've been lurking all your threads on JF for a while, good stuff.
adkfinn is offline   Quote
Old 09-22-2014, 09:13 PM   #26
Newb
 
MHawotte75's Avatar
 
Join Date: Jul 2013
Posts: 4
I so want to do that , how.much would u charge to make another one. The metal piece.

MHawotte75 is offline   Quote
Reply

Thread Tools

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 Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off




Download our Mobile App

» Featured Product

All times are GMT -5. The time now is 11:58 AM.


User Alert System provided by Advanced User Tagging v3.1.0 (Pro) - vBulletin Mods & Addons Copyright © 2015 DragonByte Technologies Ltd.

Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC