I'm thinking about making a custom airbox and was seeking ideas of the best way to go about it. I have the JWT pop charger and the heat shield is crap as many of you know.

I'm looking to design my own that mimicks the Stillen or OEM air box. I plan to use fiberglass, unless others have a better idea. I was wondering what I would use as the foundation? Cardboard? And then lay the fiberglass on both sides?

I thought maybe I can use some PVC pipe and cut it to connect the vent in the hood to the air pipe and shape curves using fiberglass as well. Just wondering with the heat in the engine, would using the cardboard and PVC pipes be okay to use since I'll be laying fiberglass over it.

 

Honestly? It would be way better just to sell your JWT and buy a Stillen if you are set on an aftermarket unit.

 

I'm just thinking it would cost more. The stillen comes with the intake tube correct? I wouldn't need it as I have the Z tube. I don't mind putting in the work, doesn't matter if it's not completely pretty looking. My main goal is for it to function better than the JWT heat shield. I guess I can always use part of that, leave the carb sticker showing as well.

 

No it doesn't. What do people sell their used Stillens for? $130? So sell your JWT for what? $100? Can you make something that doesn't look 100% ghetto for $30?

You can make one if you wish but I'm just stating it will take alot of time to to match the stillen and even more time to surpass it. You can always mod the stillen when you get it.

 

It doesn't look like it would be too difficult. I already have a pisston of fiberglass resin, matte, and bondo. I don't think it would look all that ghetto either. It will simply be a box around the filter and some sort of pathway for the air to flow from the center of the grill area to the filter itself.

Cost will be $0, if anything very minimal. I don't mind trying as working on the car is a hobby of mine so I don't see it as time wasted even if it doesn't work out. I just want to know what I should use as the foundation, or base, so that the filter is protected from heat.

 

if you want to do it, then do it, good luck

 

You could tape off of the engine bay, and use expanding foam as a mold for the fiberglass

 

If what you are saying is what I'm thinking, I'm not sure if I need to go to that extent. You're talking about completely forming it to the parts on the vehicle?

I'm not looking for anything extravagant. I'll go at it piece by piece and drill some holes, maybe make some brackets, and bolt them into some existed holes somewhere on the chassis.

I just took a look at the stillen one to refresh my memory. Were you referring to using expanding foam where the front of the vehicle is, where there is an additional air cutout for the box?

 

What I would do is cut up the stock intake box to allow for the JWT filter to be use with it while retaining the stock mounting locations, and then use expanding foam to form the sides of the box to make it fully enclosed

 

^That would look pretty siiick!!!

 

I see what you're saying. I'll pull out my OEM box under all the crap of boxes it's currently in and check it out tonight. That sounds like a lot less work and would come out better. I just hate working with expanding foam. Filled the rear deck and c pillars in my car and apparently missed some cracks and holes and things got a bit messy, though it shouldn't be the case with this.

Thanks for the tips. I'll definitely do a DIY on this and credit ya for the ideas

 

It could be done with some hot glue and cardboard too, I just find expanding foam pretty easy to work with if you know what you are doing. Use the low expansion stuff too. It cuts decently well too so you can make flat sides

 

What brand do you recommend? I've used Big Gap Filler in the past, whcih I believe is made by Great Stuff or something.

 

Basicly he wants you to do what he had been planning.

 

Really? Haha, didn't know that. I don't mind taking a stab at it. Not sure when I'll start the actual work. I'll get a good idea tonight and maybe start on it this weekend. I still have to finish up my emblemless grill.