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Want the benefits of a Cold-Air Intake (CAI) such as K&N's, AEM's, Air Raid's, et cetera, but don't have the cash to blow? Not too sure about a 'kit' off eBay? Want the satisfaction of using your hands (and tools) to create one of your own? These instructions will work for 1996 through end of production for Chevrolet Blazers, GMC Jimmys, and Oldsmobile Bravadas equipped with the 4.3 Vortec.
The following will show you how to make your own CAI, all for under $100; all with pretty common tools (and with a little help from a friend). There is no drilling required and you can return your vehicle to stock if you so wish with no signs of any modifications made! I will attempt to be as informative as possible, please feel free to reply or PM with any questions. I am by no means a professional mechanic, but that's the beauty of this modification-you don't need to be! Please read entire how-to if you intend on building one of your own as there are some different options you may choose that will affect appearance and/or price.
TOOLS NECESSARY:
Phillips head screwdriver
Flathead screwdriver
10mm wrench or 10mm deep-well socket and ratchet Hammer
Sheet metal snips (I used 7" straight snips, you may have better luck with smaller but I did not want to cut FEET of sheet metal with anything smaller)
Needle nose pliers
Scissors
Utility knife
Work gloves (if you intend on cutting the sheet metal yourself)
Sharpie marker
TOOLS NICE TO HAVE IF YOU HAVE ACCESS:
Center punch
Drill with 1/4" metal bit
Sheet metal shear
Sheet metal bender
Band saw/pipe cutter/Sawzall
3.5" metal hole saw
SUPPLIES NEEDED:
The following supplies were purchased at my local hardware store:
Minimum 24" wide by 24" long sheet metal (I used 24" wide by 30" long just to be safe)
3/4" by 1/2" corner braces (or similar hardware)
3" High-heat capable rubber coupling(usually comes with hose clamps but just in case...)
Two 3" hose clamps
Two (or more if you prefer) each of machine screws, washers, and nuts (all in same or smaller diameter as holes punched)
One sheet metal screw (see Step 2 under "Installation of Heat Shield..." for size)
4-5 feet of 3/8" fuel line (or similar high-heat capable material, i.e. hood weather-stripping)
7-8 inches of 1/4" fuel line or washer fluid hose
1 can of high heat paint (your choice of color, there are links under "Conclusion" that show the difference between flat black and aluminum)
1 tube of RTV sealant (not necessary)
3" Mandrel-bent, 45 degree pipe (I got mine from a local performance garage)
Spare cardboard lying around (a case of beer box is large and rigid enough)
DISASSEMBLY OF STOCK AIR BOX:
1. Locate the four screws that hold the top of the air box in place.
2. Loosen (but don't remove) each one with a Phillips head screwdriver.
3. Locate and remove 10mm nut on right side of air box (it's a good idea to put it back on the stud once you remove the air box as you will be re-using this).
4. Unscrew hose clamp with flat head screwdriver and remove (you will not re-use this, but hold on to it in case you decide to return to stock).
5. Place one hand on each intake pipe, lift and separate (video).
6. Grip the back of the air box, lift off the mounting stud and pull forward, then pull up and off mounting bracket connected to core support (video).
7. Looking at the core support from the cabin side you will see the mounting bracket. Grip the top tab, gently bring it towards yourself, and lift, sliding the bracket up and out.
8. You will be left with the stock air inlet on the left, and the hole where the bracket slid into on the right.
FABRICATING HEAT SHIELD:
1. Use the cardboard to make a template of the heat shield. Be sure to follow all stock contours of surrounding engine bay, as well as under hood.
2. Trace this pattern onto your sheet metal with a Sharpie marker.
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This is exactly what I'm looking for with the exception my Suburban year is 1985. Any suggestions on this truck? The person I bought it from said he had one on it but didn't have it when I bought it. Now it runs like crap, super sluggish, burns gas,etc HELP!!
i used the bottom part of the factory air box on my 05 chevy 5.3 and does awsome and the intake tube was from parts store plus filter was 80 something dollars, i love it
How To---Handmade CAI and Heat Shield
