DIY Intake

By Henry

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“Due to popular demand, I have devised instructions on how to make your own inexpensive ‘cool air intake’ from items you can find at your local home improvement store and auto store. I’d like to personally thank ‘The SpoonKing’ for giving me this idea. He, too, deserves credit. Thank you, SpoonKing.”
- Henry

The intake instructions were designed for 5S-FE engines. The test car was Henry's 1991 Celica GT Coupe. The 94+ Celica models with the 5S-FE can use these instructions, but be sure to re-measure the sizings

Materials:
1. 2” diameter PVC piping
2. 2 90° PVC elbow 2” in diameter (female/male) (part# C4807-2)
3. 1 90° PVC long turn elbow 2” in diameter (female/female) (part# C4807-LT)
Note: “Male” on the elbow means there is no flange. “Female” means there is a flange that connects a PVC pipe to another PVC pipe.
4. 1 flexible drain coupling (a.k.a. rubber plumbing nipple), 2” to 2” (part# P1056-22)
5. PVC cement (I used the Heavy Duty PVC cement)
6. PVC saw (optional)
7. 1 universal K&N cone-style filter. Be sure to get one with a 2½” nipple flange and must be no longer than 7” in length.
8. Dupli-Color Engine Paint (or any kind of paint that will withstand engine bay heat)
9. Heat reflecting wrapping (recommended)

Tools:
1. A Dremel tool w/ bits
2. Ratchet set
3. Drill

NOTE: PVC is a form of plastic. Under the conditions in the engine bay, it will not melt. Instead, it will heat up fairly quickly. Therefore, it is not only wise but recommended that heat-deflecting paint is used and/or heat reflecting wrap. If you are still skeptical about the intake melting, let me [Henry] tell you something. I live in Texas where the summers are extremely hot with temperatures that reach 100+°F. To make it worse, I drive a black car. My intake is still intact.

Table of Contents:
Step 1: Getting the materials.
Step 2: Putting the simple stuff together first.
Step 3: Cutting and sizing.
Step 4: Removing the factory intake.
Step 5: Removing stuff to get the intake in.
Step 6: Testing placement and size of the new intake.
Step 7: Making the hole for the air temperature sensor.
Step 8: Putting the intake together and painting it.
Step 9: Finishing up.

Step 1: “Let’s go shopping.” (Getting the materials):
Items 1-6 can be purchased at a home improvement store (i.e. Home Depot, Lowe’s). Look for them in the plumbing section. Items 7-9 can be purchased at an automotive store (i.e. AutoZone). The K&N filter will have to be special ordered since many auto stores do not have universals on the shelves. It is very important that the filter you order is no longer than 7 inches in length and must have a 2.5-inch nipple. They should have a K&N catalog you can look at. The filter you are looking for is in the “universal” section of the catalog.

NOTE: You have the option of using 3-inch PVC piping like I opted to use. If you decide to use 3 inch piping, all the PVC bends must be 3 inches as well. The plumbing nipple used must be a “3-inch to 2-inch” style. One of the following K&N filters will suffice if you plan on using 3-inch PVC piping:
a. Part# RU-2710 w/ rubber end, 6½” in length
b. Part# RC-2710 w/ chrome end, 6½” in length (this is the one I used)
c. Part# RU-3550 w/ rubber end, 5½” in length
d. Part# RU-3130 w/ rubber end, 7” in length (this is the one I recommend)

WARNING: If you use 3-inch PVC piping, the fuse box must be relocated to where the OEM air box/filter housing used to be. Relocation is simply done by moving and/or twisting the box into its place. DO NOT CUT ANY WIRING!!! If you plan on relocating the fusebox, be sure to fasten or brace it to something. If you do not, it will get banged around in the space provided.

Step 2: “No, it’s not time to cut stuff.” (Putting the simple stuff together first):
Items needed in this step:
· 2 90° PVC elbows 2” in diameter (female/male) (item #2)
· Rubber plumbing nipple (2” to 2”) (item #4)
· K&N filter (item #7)

Take a female/male PVC elbow (item #2) and the plumbing nipple (item #4) and connect the nipple to the male end of the PVC elbow. Be sure to unscrew the clamp on the nipple first. It will make things a lot easier. This assembly connects to the throttle body.
Take the other female/male PVC elbow (item #2) and the K&N filter (item #7) and connect the filter to the male end of the PVC elbow. Unscrew the clamp here, as well, to make the job easier. Do not tighten the filter on yet. You will have to remove the filter to paint it in a later step. This is just for testing purposes. Also, a very important note, keep the filter assembly in a place free of dirt; store it in the plastic wrapping it came with. It will be a while during the procedure before it is used again.

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