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Sezy's Gen 2 custom Cold Air Intake

Discussion in 'Gen 2 Prius Accessories & Modifications' started by Sezy, Oct 5, 2015.

  1. Sezy

    Sezy Active Member

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    2020 Prius Prime
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    Was able to snag an extra air box from this Prius at a junk yard.
    [​IMG]

    First make large cuts to remove the MAF housing and the extra tube that connects to the OEM air hose. The MAF is oddly shaped and would not allow for anything else to clamp onto it. The air intake side part will be used to fix this issue.

    [​IMG]
    [​IMG]




    [​IMG]

    I took a torch the the ends of the MAF and extra part then with a flat head screw driver started molding/pulling the melted plastic. Make sure there are no air holes or leaks. I would heat it ,mold a little then cool it off in water until I got the desired result. Used a dremel inside after wards to smooth out the inside and grinded the outside to get any plastic clumps off.
    [​IMG]


    Some of the parts I ordered. Only thing missing is a small cone air filer.
    [​IMG]


    First parts to arrive. 2" to 2.25" elbow fits fine.
    [​IMG]


    Filter came in next. Had to remove the hood insulator for this to fit. Waiting on the tubing to come in. Sounds meaner already.

    [​IMG]

    Tubes came in so time to try some test fits.

    20150927_142801.jpg 20150927_142811.jpg 20150927_142819.jpg 20150927_143939.jpg


    Looked like it was going to be as easy as a 90 silicon coupler and a long tube with a 45 bend. I was concerned it was folding the coupler too much reducing air flow. That was the least of my worries after I heard a CRUNCH CRACK from my MAF housing part I made.

    20150927_143950.jpg

    Snapped right where I joined the two parts.

    20150927_170404.jpg 20150927_170413.jpg

    Off to find a fabricator but since I'm cheap I went to exhaust repair shops first.

    Found a exhaust tube that fit in well enough then had the guy bump out the end.

    20150929_120455.jpg


    Goes down far enough it has some lip to grab.
    20150929_120508.jpg 20150929_120516.jpg

    Grinded it down so I can wedge it down futher into the plastic MAF housing.
    20150929_185334.jpg

    Covered in epoxy then painted to match.
    20151001_170400.jpg 20151001_170409.jpg 20151001_170418.jpg 20151001_170434.jpg

    Snapchat--3729745832548025685.jpg

    Decided to cut the whole area out to allow for more wiggle room. Wrapped the intake in duct tape then a old rubber coupler around the area I cut. Zip tied, wire and pipe taped it down, would rattle if I didn't. If you can get the intake tube in nice and neat then right on.
    20151004_183930.jpg

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    The intake tube was banging against what I guess is a metal coolant line so wrapped that area in Gorilla tape

    20151004_184437.jpg
    Zip tied the tube to the mount for that metal tube.
    20151004_184443.jpg




    Here is some info Tech Stream gave me when I did a quick high way run with the cold air intake in. At about 90MPH there was a 5 Nm gain in torque over the stock intake so yay but sadly the over all torque decreased. Again according to TechStream so not sure how accurate it is.

    20151004_224224.jpg

    Stock intake run 20151004_224459.jpg


    OEM intake run
    2015-10-04 22.17.55.jpg
    2015-10-04 22.20.18.jpg


    Cold Air Intake run
    2015-10-04 22.24.18.jpg 2015-10-04 22.24.02.jpg


    Wonder what Dyno results would show. We'll see if this helps at the races. More testing results will be added.
     

    Attached Files:

  2. jdenenberg

    jdenenberg EE Professor

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    Are you worried about sucking in water? Not good for your engine; water is not compressible.

    JeffD
     
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  3. 69shovlhed

    69shovlhed Surly tree hugger

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    that steel line is an a/c line. definitely don't want it to rub on that.

    as long as the filter doesn't hang below the bumper and he doesn't drive through a creek, no problem. I've had my cone filter under the rh headlight for years.
     
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  4. Sezy

    Sezy Active Member

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    Would you say my setup is ok with that line or should I cover/protect it better?
     
  5. 69shovlhed

    69shovlhed Surly tree hugger

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    I'd have to see it to say for sure, but the main thing to me is to make sure the cai tube doesn't touch the a/c line at all.
     
  6. Justdidit

    Justdidit LVNPZEV

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    Looking good! Let us know how it performs! That TechStream data is also very interesting.
     
  7. Sezy

    Sezy Active Member

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    69shovlhed made a good point so I adjusted the tubes more to the front and zip tied them. Not touching the AC line at all now. Still no Check Engine Light :)


    20151011_223847.jpg

    20151011_125328.jpg
     
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  8. Sezy

    Sezy Active Member

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    Added a heat shield/splash guard. Since lowering the car I've had to mess with the wheel well cover due to rolling fenders and figure i'll add some more splash protection. Probably not needed but makes me feel better about water coming in via the wheel well, if ever.

    20160409_220352.jpg 20160409_220313.jpg 20160409_220345.jpg
     
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  9. Justdidit

    Justdidit LVNPZEV

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    Sezy likes this.