Build your own CAI for about $100

I recently build my own CAI. It was pretty easy, required parts from Home Depot/Lowe's, AutoZone, and K&N.

AutoZone sells a 3 1/2" tube meant for the Civic/Integra 94-00 or so, purchase one of these for $45. Lowe's (or your local hardware store) can hook you up with rubber 3 1/2" tube meant for sewage plumbing, it works well for this application. You'll need one elbow and one straight connector, about 4" long, total $15. Also order from K&N or a retailer the cone filter that's about 10" long and has the 3 1/2" coupling, about $40.

You'll also need a screwdriver, some sockets and a long socket driver, a heavy duty Saws-All for cutting a bit of metal out, a jack, and about 3 hours. The Saws-All is the only item you probably won't have already, but find one, dammit! Note: Two people will make the install much easier and faster.

First, remove your driver's headlight and the battery, then jack up the drivers side and remove the wheel. Remove the plastic fenderwell (only the front part) by pulling the plastic fasteners out. You may damage a few, but any local GM dealership will have them in stock for 10 cents apiece or so. Two of the fasteners are actually metal screws, 10mm I believe, these are the ones directly behind the rotor. Hold the fenderwell in place by sticking it under the rotor for now.

Remove the stock airbox. There are two 10mm bolts holding the entire unit in place. Keep it if you plan on ever selling the car.

Remove the intake resonator; it's a plastic piece that fills the entire front fender. It's huge. You'll have to split it into two pieces to wrangle it out, all you have to do is find the seam between the part that's under the headlight and the large section, pull it apart, and both pieces will come loose. There is a 10mm metal bolt holding the bottom part in place. You can throw the pieces you remove from here into your trash can, with much happiness.

Now the tricky (but still easy) part. You'll see a triangular cutout in your metal right next to your washer fluid pipe. Several wires run through it. The side of it closest to the quarter panel is only an inch wide. Using the Saws-All, remove it. It's meant to pass the wires through, so removing this small piece will not damage anything. I went through two saw bits removing it, and it does get rather hot. Careful not to cut through the wires running through it or washer fluid pipe next to it. I recommend eye goggles and gloves. Don't get discouraged, it will take a few minutes to get through, but it's very easy to do once you locate the correct places to cut. This will give you room to stick the pipe through.

Now you're ready to assemble. Attach the small rubber coupler to the end of the K&N and fasten it very tightly. Stick the filter/coupler combo into the fenderwell, where the resonator was. Run the metal Civic inake tube through the place where you cut the metal out, and attach it in the fenderwell to the filter/coupler. Attach the rubber elbow to the top of the metal intake tube, which will be right where the stock airbox was formerly. Run your stock rubber tube that's connected to the engine into the other side of the elbow. Make sure everything is connected tightly, and reassemble the rest of your car.

I did this after already having the K&N replacing the airbox for some time, and relocating it to the fenderwell made all the difference in the world. You should now have no trouble burning rubber from a dead stop. You'll notice higher shift points and a good deal more pickup.

Happy modding! If you're interested, I can post pics. If you have any suggestions for a metal piece to replace the rubber elbow, or anything else that could make this mod even better, post it here!

yeah, post some pics..it may be interesting to see...molson is this how you made yours? It sounds rather simple, i'm just nervous about the whole cutting issue...oh well..you only live once i guess..cut her up

no, mine is All PVC. I have some Vibrant Performance tube here, gonna make a better one, after my exhaust. Mine cost 20 bucks, total..Â;-) I can slap my whole stock air unit in in about 20 mins prolly. Didn't cut a thing.

The cutting will not damage the car, and will not be visible should you reinstall the stock airbox. Will post pics soon. Molson, how big of a pipe were you able to fit through without cutting? And does it make a lot of bends?

Does any one have pics of this CAI? Does it attach to the thorttle body? I have just started mods on my car so i really need help!

yea it attaches to the throttlebody, if u open the hood the big box just in front of the idi cover and to the left is where throllte body is, that box and the hos leading to the airbox and some other tubing in the fender, i think, is removed, and replaced with 1 or 2 peice tube that improves airflow

or for about 50-60 you can make one like mine!!!

http://www.aleromod.net/gallery/AnderbrA

[johny_boy32]

thanks from a lot of people havik...i had someone ask me about this last night.

Thank Arxis who posted this in the previous forum, I'm just a messenger (but I'll take thanks for that )

[johny_boy32]

thanks goes out to arxis and you too then...

did u build it for a 2.2l ecotec engine

Originally posted by havik@Nov 18 2003, 07:33 PM

did u build it for a 2.2l ecotec engine

[Naich]

no, this is for the 3400. The setup for an ecotec or 2.4 dohc is gonna be a lot different.

do u have the custom cai setup for the 2.2L ecotec
or know anyone with it

does anybody have pics for this custom cai setup

[Naich]

this is for the 3400, not the ecotec...

There was no accompanying pics to go with this how to guide, sorry.