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Discussion Starter · #1 ·
Not sure if I can post links from other boards, but stumbled across this and it's great!! Did some looking around and didn't see anything similar but if this has already been posted I will apologize up front. I am not taking any credit for this, simple copy and paste.. All the pictures are in order from start to finish and labled 1-11, 1 being the start. Due to my max upload I am going to have to make several posts in here to complete.. So I'll get started.

"So I started treating my Powerstroke Modification Syndrome with mods to keep from going crazy. I did the 6637 mod and loved it. I decided to make the custom enclosure for it and took pictures along the way. Anyways, I thought I'd share my experience and make a DIY guide with pictures to help anyone out who wants to perform this mod. Here it is" :

First we will start off with tools and supplies. There's nothing worse then having your truck torn apart then having to put it all back together just to drive to get tools and come back to do it all over again... happens to me too often

Tools & Supplies:

.24 gauge sheet metal (Print plan layouts, tape them together, and determine how much you will need to get)
.Tin snips
.Box Cutter
.Electrical Tape
.Rivet Gun w/Rivets
.Hand Grinder w/flap disk - 80 grit + (optional)
.Drill + Drill Bits
.Standard ratchet/wrench set
.Pliers
.Screw Drivers

1.) Print out plans on 8.5 X 11 Paper. Cut on grey lines. Tape together
*If you plan on painting the finished product. Wipe down all sheet metal with vinegar or some kind of solevent to get rid of the oily stuff that is on sheet metal. It prevents the paint from sticking correctly*
2.) Use electrical tape to keep the plans still on your sheet metal.
 

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# 2

3.) Use your box knife to cut the solid and dotted (fold) lines of the paper. This leaves markings on the sheet metal for cutting.
4.) CAREFULLY cut out each layout with the tin snips. *Notice the CAREFULLY part - wear gloves! I have stitches from forgetting that step*
5.) Use Pliers (preferably ones with a large & flat head on it) to slowly bend each fold accordingly (almost all bends are 90*)
6.) Drill holes the size of your pop rivet heads through the two layers of sheet metal where you decide to secure the pieces together.
7.) Rivet all pieces together securely (Here is your initial box!)
8.) Remove your filter, battery, and battery mount.
9.) Place the box exactly where you will want it (you want your box pushed as far back as possible to ensure that you will have space for your filter when you replace your battery)
10.) Temporarily place your battery mount where it will be placed permanently and mark out holes for drilling through the box. Then Drill the holes.
11.) Place your custom box, replace your battery mount, bolt it down.
12.) Now you can replace your filter and your battery (replace filter first).
13.) Here is your final product before paint!
 

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14.) After getting to this point I went ahead and punched through the Zoodad mod for air supply.
15.) Now that I knew it fit, I pulled it all out for paint and De-sharpening. I used a grinder with a flap disk to round the corners and dull down the edges.
16.) I then primered and painted both my box and my battery mount. I used primer, then semi gloss black, then clear coat.
17.) Use previously stated instructions to reinstall.
18.) I added an air ram tube that I custom made from some flexible gutter tubing. It worked great and fed right from the Zoodad into the box. This really helps!
19) And Here is the final product with the Filter Cover.


That's it!!! Hope this helps if this is what you were looking for :drinking3:
 

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Nice!! I'll have to do this when I get home from deployment.
 

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Discussion Starter · #7 ·
Nice!! I'll have to do this when I get home from deployment.
Sounds great, I can't wait myself. Make it home safe and THANK YOU for your service sir!!

:usa:
 

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Here is a picture of my finished product. Sorry engine bay hadn't been cleaned yet and inter cooler pipes hadn't been painted.
 

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Here is a picture of my finished product. Sorry engine bay hadn't been cleaned yet and inter cooler pipes hadn't been painted.
That's awesome!! I'll post pics once mine is done, my intake is just getting here today, expected I would be building last weekend. Nice job!!
 
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