Install: POSR ABS 3'' intake

[JoeWagon]

Well here was my attempt to rig up a true POSR style intake. 2g.
Pre-flight thoughts
Replacing the accordian style small intake is a must. There are some things to worry about for this project. Your valve cover vent, BCS, and charcoal canister tubes are connected to the stock intake. I let them all just hang down, which is not savvy with emissions people. I didn't forsee any problems with the car by doing this, so maybe 95 GSXracer will reply and let me know.

On a side-note, the inner stock intake was mostly blocked by the BOV recirc on the inside. That means it restricts flow A LOT: there's a giant tube in the way of airflow. Also, there was a lot of silty dirt inside, some of it was wet with oil from the valve cover vent. May have been a problem with previous or current filters too?

Materials
4''-3'' rubber coupler.
(2x) 45 degree elbows.
3''-2'' rubber coupler.
1-1/4'' hose barb. (Home depot won't have these - but my local plumbing/heating store did)
~6 inches 1-1/4'' hose to lengthen BOV dump tube. NOT SHOWN
3 inches of 3'' ABS pipe. NOT SHOWN


Making it
Attaching all parts together, with the 45 elbows in opposite angles, was just too damn long. Notice how small the 2'' is compared to the rest of the intake? T"too-small"25
1. I cut off the fat parts of the elbows (on both sides) so I could slip on the couplers without using spare pipe. Cut it to maintain the angle, so straight down, not even across the pipe.

2.Consider filing down the factory symbols on the elbows to get the couplers to fit (you'll know what i'm talking about if you do it, there are protruded plastic symbols that prevent the couplers from sliding on).

3. You'll have the 3 inches of pipe connecting the elbows. There happens to be 1.5 inches of female-ness to every ABS connector... so two females are joined by a round number, 3. Imagine that.

4. Dry fit the whole thing and make any adjustments you need to the angles (I didn't) You may want to make it a bit longer between the elbows if your filter is smaller than a huge K&N. Try whatever you'd like.

5. BOV recirc. I haven't done it yet, will do tomorrow.
Finished Product, on the floor


Finished Product, installed. You should have no trouble using the band clamps that come with the ABS couplers. I was able to secure the round 4'' onto the OVAL 2gMAS, make sure it doesn't leak there.



Test drive
The car pulls like a mother. Being my only modification other than a conical filter, it made a decent difference in power. I was able to get a couple strong launches in, and on wet spots and/or turning, all 4 tires would spin.
Well I didn't connect the BOV recirc. I have problems with idle, and when I let off the gas the car is jumpy, must be due to the richness? Oh yeah, and when I put it in neutral at over 3k RPM, the car dies in motion. Under 3k, the RPM dips near 0. Seems too like it gives it gas right after I get off the accelerator, which at high rpm BUILDS BOOST so it's a cycle that won't stop. Causes jolting.

Problems
1.BOV return. I'm going to drill a 1-1/8'' (tad smaller than threads on the barb) hole somewhere in this pipe soon. It's not easy since there's really no straight pipe to do it in, so it has to be exact. Then using the hose barb, thread the pipe similar to a tap and die (you've used one, right?).
2. Turbo Oil supply (or return) line touches the 3''-2'' coupler. You'll have to use some force getting the coupler onto the turbo good enough for a seal, but I did it.
2. Radiator hose touches, not really a problem, just thought that I would mention it. Thanks Mitsu, nothing else fits in my car other than stock parts.

[EclipseRST]

bump... this is a usefull thread, and if you feel like it Joe, either make it a sticky or copy and paste into a sticky!!

[JoeWagon]

If my thread dies without any views, i'll sticky it for a while