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Old 01-09-2012, 11:19 AM   #1
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Excellent Hi Flo intake mod

So I was reading Pedro's Hi Flo intake mod and wondering about the best materials to use. A shop here in the UK sells the item pictured below and I thought if I could get the parts cheap this one would look and perform great.

I looked on ebay and saw that you can buy the 76mm 45 and 90 degree polished alloy angles plus rubber connectors and stainless clips very cheaply in comparison to buying the finished product. I bought mine all from the same seller

Here are links to the parts I bought.

eBay - The UK's Online Marketplace

eBay - The UK's Online Marketplace

eBay - The UK's Online Marketplace

eBay - The UK's Online Marketplace

I started by cutting the lips off each end of the angled pipes then I put them next to original pipe I had removed from the car to check the length was ok.
It worked out that once I joined the two pipes in the middle I just had to shorten the ends to make it fit (more off the 45 degree angle than the 90). It took two attempts to get the shape right so it fitted to the car properly. It is better to cut off too little and be able to cut off a bit more than just chop off a big piece and ruin it. Also you might want to slightly angle your cuts to make it fit more accurately.
I used a full 100mm rubber for the join and cut one in half for each end.
Fitting it to the car was a bit of a fiddle. The pipe exiting the airbox is slightly wider than the 76mm hose. I suggest that you start by putting the shortened rubber on here and tighten the clip then assemble the rest of the unit working up wards rowards the engine. Make sure you point the screws on the hose clips in the direction you can get at them afterwards. In the end I left all the hose clips a bit loose and wriggled it around until it went on then tightened the clips up when I was happy it wasnt touching anything (engine or car body). Here is a picture to show the end results.

A pretty nice job I thought! It cost a total of about 55 and took me 1-2 hours to make. The parts were good quality from this ebayer. All I used was a flat screw driver, a hack saw and a file to clean the pipe cuts up and a craft knife to cut the hose.

I took it out for a run and the butt dyno says its a big improvement. No real change to the sound but it seems to rev much more cleanly especially at high revs.
I havent checked to see if anyone is selling these parts in the US but I'm sure if you nosey around you'll find them (or order them from this very nice chap in the UK)

A final note. Please make sure you remove all the aluminium swarf from the pipes before you assemble it on the car. I put mine in the washing up bowl when the wife wasnt looking and gave it a thorough scrub inside with detergent to remove and dirt and alloy particles then dried it properly. I think you may end up very sorry if you dont do this.

A big shout out to Pedro for the inspiration! I hope this is useful to someone.


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Old 01-09-2012, 05:14 PM   #2
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That looks great. Good job.
2004 Boxster S, Guard's Red, 6 Speed
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Old 01-09-2012, 07:44 PM   #3
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Very nice! Looks like a fun project. What are you using for a filter?
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Old 01-09-2012, 10:57 PM   #4
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thanks guys, I am using a K & N also off ebay :-)
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Old 01-10-2012, 07:40 PM   #5
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Looks good, any pictures with it installed in the car?
"Trying to drive a Boxster S for team CoolCava Racing!"
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Old 01-12-2012, 01:26 AM   #6
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i'll take some shortly and post them
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Old 01-13-2012, 07:02 PM   #7
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Very nice! Thanks for sharing!
'14 Boxster
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