VIDEO: F-250 Enlarging Cold Air Intake Using Existing Parts Cheap And Easy 2000 F250 5.4 Liter
The air intake hole on my F-250 is 2-1/2" diameter. That is smaller then the throttle flap in the valve body. I looked at the components and decided to fabricate a new larger inlet pipe using the same filter housing and mounting bracket. I took two 3" ABS pipe couplers, and cut the outside half of one a quarter inch deep using a hole saw. I then used a larger hole saw to cut the outer diameter half way in and a quarter inch deep. I then took ABS glue and glued the two couplers to each other with the half inch overlap. I then took a 4" angle grinder and ground the bracket opening to 3-1/2" and also removed the small existing pipe on the filter housing going through the grill for cold air intake then drilled it larger with the 3-1/2" hole saw. I then stuck the ABS pipe into the new large opening on the filter housing and placed it as far forward into the housing as I could without pushing through. I still need to get some 1/2" to 3/4" rivets with backing washers and short metal strips, then drill holes for solidly connecting the filter housing to the pipe. The Blue RTV silicone you see is holding very strong as is in the video but adding the rivets will make it more solidly connected. I will do three rivets, 120 degrees of rotation apart to make the connection stable. It took a couple hours to do the project. A little oil on the plastic and rubber gromets on the underside of the filter housing bracket, will let you with some effort, pull the housing apart from the bracket. Clean the bracket, create your larger opening as neatly as possible. I used a 4" angle grinder. Grind, sand, de burr, then spray the whole bracket with black paint, 2 coats on the parts with bare metal. Stay tuned for updates on all the projects being done to upgrade this truck...
