Improving the Airaid CAI

Jeff's FRC · Nov 9, 2015

First, I'd like to apologize for making yet ANOTHER cai thread, but I think a few guys would benefit from a few pics and an explanation of what I did. :thumbsup:

Imo, the Airaid has the best design with the closed box setup. I've seen countless guys complain of high IAT's with open box setups and even seen guys on this forum get cooler IAT's from making plexiglass toppers for their JLT's. I don't want to start a debate on CAI's, just wanted to give MY reason for going with the Airaid.

I'll be getting a tune, so I decided to remove the molded insert to get a bigger diameter tube making my Airaid a "tune required" intake. The pic below is what it will look like after taking a Dremel with a cutoff wheel to the end of the tube. After the Dremel, I had to take a hacksaw blade and saw into the tube through the slit I made with the Dremel to get through some of the plastic from the injection molding process.

Here is the insert removed.

Here is the tube after some sanding work. It'll be self explanatory what you need to do after you get the insert out.

To finish it off, I removed the Airaid gel logo on the tube and replaced it with a Ford gel logo that I got off eBay. I also removed the ugly aluminum trim panel that goes over the plexiglass. To remove the aluminum cover, you will need to shorten the button screws or just add 1/4" lock washers. The screws supplied by Airiad are 1/4-20x1/2". The hardware store by me didn't have any 1/4-20 hardware shorter than 1/2", so I just went the lock washer route.

BOBS550 · Nov 9, 2015

Thanks for sharing, it came out looking GREAT! Let us know how the tuning goes the FORD sticker is perfect.. :thumbsup:

BKinn · Nov 10, 2015

Looks fantastic. The Ford sticker is the icing on the cake. I always hated how cheap the Airaid looked on these. Makes it look OEM!

jrt6 · Nov 10, 2015

Where did you get the Ford decal from? I'd love to get one as well!

Chameleon · Nov 10, 2015

Nice job, that come out great!

Evo_Rob · Nov 10, 2015

So, that little insert is what causes the necessity for a tune? I can't imagine that restricts enough for that.

Coaster · Nov 10, 2015

Evo_Rob said:
So, that little insert is what causes the necessity for a tune? I can't imagine that restricts enough for that.

You have to understand how a MAF works. It measures the airflow across the sensor, that is all it knows. The car then calculates total airflow based on the reading from the sensor and knowing the diameter of the tube the sensor is installed in.

If you inset the MAF in a 5" tube instead of the factory 4" tube there is now more air flowing through the tube at a given velocity reading from the MAF. This is why you need a tune, to change how the car calculates airflow.

So the only thing the insert in the Airaid or any other intake that uses a restrictor does is choke the tube down to the factory diameter so the MAF readings are what the factory calculations expect.

Evo_Rob · Nov 10, 2015

It just doesn't seem like that thin of a restrictor wouldn't do much. I do understand the principal of it though

D.Brown · Nov 10, 2015

Is there a whistle with this intake as well at partial throttle that's audible with the windows down?

Jeff's FRC · Nov 10, 2015

jrt6 said:
Where did you get the Ford decal from? I'd love to get one as well!

I got them off eBay. They measure 3.5"X1.5"
http://m.ebay.com/itm/2-NEW-FORD-ho...o-gt-taurus-/291534284456?txnId=1228517721019

They come in a package of two.

Evo_Rob said:
It just doesn't seem like that thin of a restrictor wouldn't do much. I do understand the principal of it though

The picture of the insert is a little deceiving. It's really thin, but it closes the diameter of the tube more than it appears because it doesn't sit flush with the ID of the tube. I didn't measure the ID of the insert, but I just measured the ID of the Airaid tube without the insert, and it looks to be about 108mm. I believe the stock diameter is 85mm so that's quite a difference in the ID of the intake tube from stock to Airaid without insert.

D.Brown said:
Is there a whistle with this intake as well at partial throttle that's audible with the windows down?

Not sure, and I won't have it installed till spring so hopefully someone can chime in and answer for you.

Evo_Rob · Nov 10, 2015

Right on. It's definitely deceiving to me haha.

cbrtrx · Nov 10, 2015

Thats the first thing I did when I got my airaid, it absolutely requires the maf to be calibrated.

Old Car Guy · Nov 16, 2015

Ford Emblem........

Jeff's FRC said:
First, I'd like to apologize for making yet ANOTHER cai thread, but I think a few guys would benefit from a few pics and an explanation of what I did.

Imo, the Airaid has the best design with the closed box setup. I've seen countless guys complain of high IAT's with open box setups and even seen guys on this forum get cooler IAT's from making plexiglass toppers for their JLT's. I don't want to start a debate on CAI's, just wanted to give MY reason for going with the Airaid.

I'll be getting a tune, so I decided to remove the molded insert to get a bigger diameter tube making my Airaid a "tune required" intake. The pic below is what it will look like after taking a Dremel with a cutoff wheel to the end of the tube. After the Dremel, I had to take a hacksaw blade and saw into the tube through the slit I made with the Dremel to get through some of the plastic from the injection molding process.

Here is the insert removed.

Here is the tube after some sanding work. It'll be self explanatory what you need to do after you get the insert out.

To finish it off, I removed the Airaid gel logo on the tube and replaced it with a Ford gel logo that I got off eBay. I also removed the ugly aluminum trim panel that goes over the plexiglass. To remove the aluminum cover, you will need to shorten the button screws or just add 1/4" lock washers. The screws supplied by Airiad are 1/4-20x1/2". The hardware store by me didn't have any 1/4-20 hardware shorter than 1/2", so I just went the lock washer route.

I want to take this time to THANK JEFF, he has been so much help telling were to find the Ford Emblems, and I have put mine on today..... Wow it is so much better looking then the Airaid Emblem, you guys and gals will love this cheep mod........
JEFF AGAIN THANKS..... Your a good Man..... John :cheers: :thumbsup:

Jeff's FRC · Nov 16, 2015

Old Car Guy said:
I wand to take this time to THANK JEFF, he has been so much help telling were to find the Ford Emblems, and I have put mine on today..... Wow it is so much better looking then the Airaid Emblem, you guys and gals will love this cheep mod........
JEFF AGAIN THANKS..... Your a good Man..... John :cheers:

Anytime John glad I could help ya out :thumbsup:

Nick@JDM · Nov 17, 2015

Very interesting to see this thread!

We did the same thing a few months ago. After testing with the JLT Intake and saw some gains with the larger MAF housing we modified an Airaid kit just like you did. We also added the Ford emblem and made our own tinted box cover to give it a nicer look.

We have a great tune developed for this intake combination for manual and automatic cars as well. Our car is an auto so we spent a lot of time and R&D on that tune. It is pretty kick ass.

2015 Mustang GT JDM Custom Tuning

Here are some pictures of our finished product:

Improving the Airaid CAI

Jeff's FRC

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BOBS550

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BKinn

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jrt6

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Chameleon

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Evo_Rob

Mmm... Boost...

Coaster

RallyNorthAmerica.com

Evo_Rob

Mmm... Boost...

D.Brown

Save the Manuels

Jeff's FRC

Well-Known Member

Evo_Rob

Mmm... Boost...

cbrtrx

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Old Car Guy

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Jeff's FRC

Well-Known Member

Nick@JDM

Well-Known Member

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