Air Intake

[purduefarmboy460]

I'm trying to figure out how some of these guys make their own intakes for their 7.3s I have seen pictures of stuff, but never really any good ideas or instructions... any ideas, lets think cost effective

[99Smokin73Stroker]

I'm with you on this one!! But I have limited knowledge so far, that's why i'm on here! I really don't see the sense in some of the diesel products out there being so expensive. I mean come on, 4 or 500 bucks i've heard for an AFE gen II? So what if it's the best! I'd give 300 maybe, and that's a big maybe. I'm not cheap, I buy the best so I buy it once, but I think some things are just more than they should be. Some of these companies might actually make more profit by selling their products for a little, or a lot less than the msrp they've greedily come up with because so many more enthusiasts would be able to buy it without waiting after 5 paychecks!

[Oreo]

Actually after a LOT of research and reading I decided to go with the Ford Factory AIS setup which is designed and build by Donaldson. It flows as well at the AFE in testing, fits like a glove and the filtration is excellent. Takes about 30 - 45 minutes to install and believe it or not it’s only $188.75 from powerstrokeshop.com which is a Ford dealer in Indianapolis.

There are a couple mods you can do to the system that allows the unit to pull cool air from the front grill as well as from the fender well like the older diesels. The front grill mod is called the ZooDad Mod named for the inventor from another forum. If you ever noticed the snorkel from the intake points to the back of a fiberglass support which blocks the cooler outside air from entering the system. The mod is to cut or in my case drill the support inline with the snorkel to allow air to flow or at highway speeds be forced into the system. The size of this opening is dependent on your preference. I drilled two 2 1/2” holes in this support. This is a quick, easy mod that takes about 30 - 45 minutes to do and the best part it cost nothing to do.

The second is a mod to the AIS air box itself. This mod places a 3 1/2“ hole in the AIS unit allowing for added air flow and less restriction. The guys at dieselpowerproducts.com are selling a foam sleeve to seal the AIS box to the fender opening which prevents the hot under hood air from being pulled into the system. The cost of this sleeve is 23.50 and if you are creative you can fabricate your own.

So for around $213 you can have a great flowing intake setup, lower EGT (oh I forgot to mention that), functioning filter minder and the piece of mind that you still have the proper filtering protection for your Power Stroke.

Nothing kills a diesel quicker then a dust bath from improper filtration.

[Ramsmoker]

I have refined the zoodad mod by building a airhorn from the end of the factory tube, thru the core support and up to the grille. I pulled the breather hose from the intake hose between the air box and the turbo. Turn the breather around so the fitting points to the back. Run new 3/4 plastic hose down the frame to the back of the trans. Weld a 3/4 tube into your exhaust and form it over to the left frame rail and connect to the plastic line. This is a old drag racer trick. Use your exhaust to take the pressure out of the crank case. If you want to test the therory, just listen to the engine. the factory way, open to air and under vacume. my next mod for the intake is to replace the factory hose from the air box to the turbo. Check out www.intakehoses.com.

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Last edited by Ramsmoker : 10-18-2005 at 12:31 AM.

[Rodslinger]

I thought about doing the Zoodad myself but I was concerned with crud or water getting up in there. Sounds like you've done a heck of a job mod'ing the whole Zoodad setup there Bill!
Did either of you guys notice any difference after your mods?

[Ramsmoker]

The first one I got serious about was my wifes midlife crisis car, a Mustang GT convertable. I used a 1984 Ltd air horn and cut the air silencer larger to slip the 4" tube into. At about 30mph the car would surge. I took it in on warranty and Ford tweeked the ECM till it stopped. Back to the Excursion now. Yes it does make a difference from even 20 mph. I find a few bugs in there but never any water and it rains alot in the Seattle area. Last time I cleaned the K&N I popped the grill out and pushed a damp rag through to the air box. Fire yours up without the air cleaner and put your hand on the intake tube. They suck pretty hard. I feel that if I can jam more air down its throat the better it will run. My next mod is to take the snake rubber tube out of the system. That web site I listed has just the ticket. A smooth straight shot has to complement what has been done to this point.

[dulliesmoke]

here is the thing, my roomate has a cummings and all the stuff he reads says that k&n filters are bad bad for the diesel. is this a dodge thing, are they all wrong, is there a better filter? im just looking to get better milage and power out of my oil burnner!

[Ramsmoker]

I don't know what to tell you. If you write all the filter people which I have, they will product charts showing how there filter holds back more material and flows more air than brand X. The variations I have seen are nothing new. Just old designs reintroduced. Most all the performance filters are cotton gauze of different colors frame work and some with foam. It would be cool to see them all on the same flow bench to see. Some dealers are claiming the oil coated filters ruin mass-air meters in gas engines. Again, I have never seen proof to this.

[Oreo]

I have read a lot about filters and as you have stated there are many references to the K&N's not filtering dust properly for a Diesel. I ran a FIPK kit on my 95 F-150 w/351w. I can tell you from personal experience that every time I cleaned the filter and reoiled it I would see dusting in dual intake tube system. When I purchased my 02 Powerstroke and started reading about filters and upgrades, K&N wasn't even an option for me from my experience with it and my F-150. Dusting is the number one killer of diesels. After months of reading and counting coins I decided to run the Ford AIS system with the ZooDad and fender mods. This allows for the best filtration of air while also allowing for the increased air flow needed for our mods. The AIS system is one of the best flowing systems available, it is also cost effective, easy to install and when the hood is opened by the dealer it looks completely factory but we know what it really hiding...

[Ramsmoker]

I have seen the dusting in my tube also. It wasn't as alarming as the crap that came from the CCV!!! After modifing my oil aplication method to get better coverage I don't see any dusting now. As for air flow, I don't have a flow bench to set my system up to. I have allways been a proponet of ram air, the oldest trick in the book. Hold your hand over the air intake and tell me what you feel. I know, I have done this and at 2500 it will eat your hand. I have two of my "Ramsmoker" freshair intakes up an running. I'm working on adapting different air filters in the box so you can change to this and keep your currant filter. Hope you didn't throw your stock box away. This is a 4" from the grill to the turbo. This is seat of the pants. I never get turbo surge or cavitation. I need to get off my @%$& and put the wicked wheel on.