Air intake/cleaner mod - Diesel Place : Chevrolet and GMC Diesel Truck Forums
 
Home Forum Market Place Garage Tuning Library DTC Tool Register Vendors
Go Back   Diesel Place : Chevrolet and GMC Diesel Truck Forums > GM Diesel Engines > 6.2L Diesel Engine
Register FAQ Forum Rules My Replies My Threads Mark Forums Read Advertise

6.2L Diesel Engine Discuss the 6.2 GM diesel engine & associated components.

DieselPlace.com is the premier Duramax Diesel Forum on the internet. Registered Users do not see the above ads.
Like Tree1Likes

Reply
 
LinkBack Thread Tools
Old 06-27-2005, 02:25 PM   #1 (permalink)
TFLundyB275
Eagle Eyes
 
TFLundyB275's Avatar
 
Join Date: Feb 2005
Posts: 1,329
iTrader Score: 0 reviews

Air intake/cleaner mod

I just finished making my own aircleaner. I wanted to let the engine breathe easier, with unrestricted, cooler outside air, so I wanted to increase my inlet size. The intake muffler was off already, but even like that it was 4" dia at the radiator support, going to a 2" dia to fit the 2"x4" oval in the factory aircleaner.

Since the 2"x4" oval aircleaner inlet was maxed out with the factory setup, I had to go bigger. Was decided that I could stack (2) 3" filters, with the orginal size diameter of the orginal 4". So with 6" filtration, I could increase my inlet from 2" height to a full 4" diameter opening.

I didnt want to cut up my old base, and I had free sheetmetal to use. I used the old base as a model and just increased the height of the sides really. using the base as a model was key, since its designed to fit over the 2 cdr tubes that go to the intake. Also, I was able to use the original cover, and i painted it all glossy black.

So while making it, I remembered that there was a second air intake opening on the radiator support, located on the drivers side. Because of the longer HD radiator, it is partially blocked by it, as well as the aux battery. But I thought I could still get to it, and besides it cant be any worse then the orginal factory air intake. So instead of cutting 1 4" circle in my new air cleaner, I cut 2 for a dual inlet setup.

the truck orginally had the inlet box which seperated air and water. It looked pretty restricting, so i went to the junkyard and bought 2 of the standard straight through design inlet connectors, the kind that roatates in. they are a tad larger then 4" diameter, so that worked out as well.

I had to make 2 new cover bolts, since with the increase of height they became shorter. I just cut a 6" piece or rod, threaded the one end for the orginal wingnuts and wielded a bolt to the other end. worked like a charm.

for new intake hose i used 4" aluminized clothes dryer duct. unrestricted, flexable and its fire resistant it worked great. hose clamps on both ends.

like imagined, the second intake was a real pain to install. I couldnt get the hose on with the radiator in the way, so its partially past the support but its still in there tight. Plus with alot of bends... going down and around the battery tray, then back up and over the ac compressor. One of the bends is pretty tight. but from what i can see its still holding a 2"-3" diameter. the dryer duct helps hold that shape, and its stronger then imagined, on more the one occasion I thought it would get cut.

So even though the secondary is not true 4" and its got a few bends, it has to be equal to the factory setup, and even if it helps breathe alittle, then its worth it in my opinion.

let alone, it looks really cool to see dual inlets go into that aircleaner!

One problem I imagined would happen, but didnt. the orginal aircleaner has a detent in the front to clear the fuel return line on the IP. I didnt add on to my design, and it just clears it. Possibly the new cleaner sits a tad taller of the intake manifold. Just to be sure, I added a piece of hose there to protect it.

one small problem was that i was a bit off on my new height for the sides, the filters didnt stay in place. a solid clean piece of cardboard fixed that problem.

being recently finished I havent driven it around much yet, but on my one drive it seems the speedometer likes to move up faster then it used to, especially in the higher range. there also seems to be a difference from standstill takeoff. I will update on differences when they come, plus I might have to tow a boat soon so that will be interesting to see if any improvments.

most people I asked about stacking airfilters, was that it was pretty noisy. I have not experienced any of that yet and I doubt I will. besides, if it does happen....the louder the better!

the cost was barely any. sheetmetal, the rod(for the bolts) and the means to weld it was free. dryer duct was around $11, and it came in 8' lengths, which was enough for both inlets, but not by much. 4 hose clamps, about $1.25 each. and the paint. the 3" filters are about $5.25 each.

What does everyone think? Any questions, ask and I will get back to you.

__________________
1985 K20 Chevy pickup, 6.2L N/A C code with J code 4544 IP&intake, Fluidampr, 2qt oil filter, dual early spin on fuel filters with inline heater
CS144 140amp alternator with dual belt pulley + military pulley modification + belt tensioner, Autometer Tachometer, headlight relay upgrade
4/0 starter and crossover cables, THM700R4 w/ cooler, NP208, 3.73 s/f, C30/1 ton springs (3 front, 9 rear)
Superwinch locking hubs, front & rear Eaton Positraction, BFG Commercial Traction 235/85/R16E tires,
dual 2.5" glasspack exhaust, Z75 quad front shocks, Class IV 12000 lbs GTWR trailer receiver, headlight relays, CB and Ham Radio.
----------
2019 Chevy 1.6L TurboDiesel Equinox LT AWD
----------
Allis-Chalmers CA, Case 530CK Loader/Backhoe with 188D 3.1L N/A Diesel engine, Eager Beaver 5 ton dual axle trailer, MEP002a Onan Diesel generator
Offline  
Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 06-27-2005, 02:34 PM   #2 (permalink)
mangus580
Diesel Head
 
mangus580's Avatar
 
Join Date: Feb 2005
Location: Williamson, NY
Posts: 735
iTrader Score: 0 reviews
Send a message via ICQ to mangus580 Send a message via AIM to mangus580 Send a message via Yahoo to mangus580

Got Pics??

__________________
Mike

-'86 M1009 CUCV 6.2l J-Code - 700R4 - 3.08/10 bolt(Daily Driver)
-'70 M35A2
-'99 K2500 Suburban 6.5l F-Code - 4L80E - 3.73(Wife's)

Member #1 of the Zip Tie Boost Sensor Club
Offline   Reply With Quote Quick reply to this message
Old 06-27-2005, 03:14 PM   #3 (permalink)
TFLundyB275
Eagle Eyes
 
TFLundyB275's Avatar
 
Join Date: Feb 2005
Posts: 1,329
iTrader Score: 0 reviews

pictures

Yes, I forgot to mention that. I will have pictures when it stops raining.
__________________
1985 K20 Chevy pickup, 6.2L N/A C code with J code 4544 IP&intake, Fluidampr, 2qt oil filter, dual early spin on fuel filters with inline heater
CS144 140amp alternator with dual belt pulley + military pulley modification + belt tensioner, Autometer Tachometer, headlight relay upgrade
4/0 starter and crossover cables, THM700R4 w/ cooler, NP208, 3.73 s/f, C30/1 ton springs (3 front, 9 rear)
Superwinch locking hubs, front & rear Eaton Positraction, BFG Commercial Traction 235/85/R16E tires,
dual 2.5" glasspack exhaust, Z75 quad front shocks, Class IV 12000 lbs GTWR trailer receiver, headlight relays, CB and Ham Radio.
----------
2019 Chevy 1.6L TurboDiesel Equinox LT AWD
----------
Allis-Chalmers CA, Case 530CK Loader/Backhoe with 188D 3.1L N/A Diesel engine, Eager Beaver 5 ton dual axle trailer, MEP002a Onan Diesel generator
Offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 06-27-2005, 03:16 PM   #4 (permalink)
mangus580
Diesel Head
 
mangus580's Avatar
 
Join Date: Feb 2005
Location: Williamson, NY
Posts: 735
iTrader Score: 0 reviews
Send a message via ICQ to mangus580 Send a message via AIM to mangus580 Send a message via Yahoo to mangus580

Rain? Sure would like some of that!!! Damn its hot.
__________________
Mike

-'86 M1009 CUCV 6.2l J-Code - 700R4 - 3.08/10 bolt(Daily Driver)
-'70 M35A2
-'99 K2500 Suburban 6.5l F-Code - 4L80E - 3.73(Wife's)

Member #1 of the Zip Tie Boost Sensor Club
Offline   Reply With Quote Quick reply to this message
Old 06-27-2005, 05:26 PM   #5 (permalink)
TFLundyB275
Eagle Eyes
 
TFLundyB275's Avatar
 
Join Date: Feb 2005
Posts: 1,329
iTrader Score: 0 reviews

picture number 5 is the one showing how tight the secondary inlet is, with the battery holder and the radiator in the way.
Attached Images
File Type: jpg truck.jpg (24.1 KB, 1506 views)
File Type: jpg air1.jpg (34.8 KB, 2792 views)
File Type: jpg air2.jpg (36.8 KB, 1961 views)
File Type: jpg air3.jpg (31.5 KB, 1856 views)
File Type: jpg air4.jpg (31.7 KB, 2013 views)
File Type: jpg air5.jpg (28.2 KB, 2054 views)
__________________
1985 K20 Chevy pickup, 6.2L N/A C code with J code 4544 IP&intake, Fluidampr, 2qt oil filter, dual early spin on fuel filters with inline heater
CS144 140amp alternator with dual belt pulley + military pulley modification + belt tensioner, Autometer Tachometer, headlight relay upgrade
4/0 starter and crossover cables, THM700R4 w/ cooler, NP208, 3.73 s/f, C30/1 ton springs (3 front, 9 rear)
Superwinch locking hubs, front & rear Eaton Positraction, BFG Commercial Traction 235/85/R16E tires,
dual 2.5" glasspack exhaust, Z75 quad front shocks, Class IV 12000 lbs GTWR trailer receiver, headlight relays, CB and Ham Radio.
----------
2019 Chevy 1.6L TurboDiesel Equinox LT AWD
----------
Allis-Chalmers CA, Case 530CK Loader/Backhoe with 188D 3.1L N/A Diesel engine, Eager Beaver 5 ton dual axle trailer, MEP002a Onan Diesel generator

Last edited by TFLundyB275; 06-27-2005 at 05:40 PM.
Offline   Reply With Quote Quick reply to this message
Old 06-27-2005, 05:29 PM   #6 (permalink)
mangus580
Diesel Head
 
mangus580's Avatar
 
Join Date: Feb 2005
Location: Williamson, NY
Posts: 735
iTrader Score: 0 reviews
Send a message via ICQ to mangus580 Send a message via AIM to mangus580 Send a message via Yahoo to mangus580

Looks GREAT!!!
__________________
Mike

-'86 M1009 CUCV 6.2l J-Code - 700R4 - 3.08/10 bolt(Daily Driver)
-'70 M35A2
-'99 K2500 Suburban 6.5l F-Code - 4L80E - 3.73(Wife's)

Member #1 of the Zip Tie Boost Sensor Club
Offline   Reply With Quote Quick reply to this message
Old 06-28-2005, 12:10 AM   #7 (permalink)
cougarjohn
 
Join Date: Dec 2003
Posts: 274
iTrader Score: 0 reviews

Filter mod.

You did a great job!!!! I would suggest that you replace the cardboard spacer with a solid rubber spacer. The cardboard will eventually collapse enough to leak air. The air filters come with a rubber mounting so one or two glued together if necessary might work.
Offline   Reply With Quote Quick reply to this message
Old 06-28-2005, 12:58 AM   #8 (permalink)
TFLundyB275
Eagle Eyes
 
TFLundyB275's Avatar
 
Join Date: Feb 2005
Posts: 1,329
iTrader Score: 0 reviews

Thanks guys!
I was trying to figure out a easy way to do better then the cardboard. A guess would be that im only off 1/8". I tried to get it so with the lid pushing everything down, it would smash the cardboard solid and make a firm seal.

What are these rubber mountings that come with the filters?

I believe my measurement is off due to making the lip for the cover. i took in account for it, but being first time metalworking, some of the finished product isnt really 100% accurate.

I think I still have a drawing and measurements for anyone who is interested.
__________________
1985 K20 Chevy pickup, 6.2L N/A C code with J code 4544 IP&intake, Fluidampr, 2qt oil filter, dual early spin on fuel filters with inline heater
CS144 140amp alternator with dual belt pulley + military pulley modification + belt tensioner, Autometer Tachometer, headlight relay upgrade
4/0 starter and crossover cables, THM700R4 w/ cooler, NP208, 3.73 s/f, C30/1 ton springs (3 front, 9 rear)
Superwinch locking hubs, front & rear Eaton Positraction, BFG Commercial Traction 235/85/R16E tires,
dual 2.5" glasspack exhaust, Z75 quad front shocks, Class IV 12000 lbs GTWR trailer receiver, headlight relays, CB and Ham Radio.
----------
2019 Chevy 1.6L TurboDiesel Equinox LT AWD
----------
Allis-Chalmers CA, Case 530CK Loader/Backhoe with 188D 3.1L N/A Diesel engine, Eager Beaver 5 ton dual axle trailer, MEP002a Onan Diesel generator
Offline   Reply With Quote Quick reply to this message
Old 06-28-2005, 08:33 AM   #9 (permalink)
mangus580
Diesel Head
 
mangus580's Avatar
 
Join Date: Feb 2005
Location: Williamson, NY
Posts: 735
iTrader Score: 0 reviews
Send a message via ICQ to mangus580 Send a message via AIM to mangus580 Send a message via Yahoo to mangus580

Sure am!!
__________________
Mike

-'86 M1009 CUCV 6.2l J-Code - 700R4 - 3.08/10 bolt(Daily Driver)
-'70 M35A2
-'99 K2500 Suburban 6.5l F-Code - 4L80E - 3.73(Wife's)

Member #1 of the Zip Tie Boost Sensor Club
Offline   Reply With Quote Quick reply to this message
Old 06-28-2005, 11:26 PM   #10 (permalink)
TFLundyB275
Eagle Eyes
 
TFLundyB275's Avatar
 
Join Date: Feb 2005
Posts: 1,329
iTrader Score: 0 reviews

Mike, cool. I will find it and post it soon as I can.

__________________
1985 K20 Chevy pickup, 6.2L N/A C code with J code 4544 IP&intake, Fluidampr, 2qt oil filter, dual early spin on fuel filters with inline heater
CS144 140amp alternator with dual belt pulley + military pulley modification + belt tensioner, Autometer Tachometer, headlight relay upgrade
4/0 starter and crossover cables, THM700R4 w/ cooler, NP208, 3.73 s/f, C30/1 ton springs (3 front, 9 rear)
Superwinch locking hubs, front & rear Eaton Positraction, BFG Commercial Traction 235/85/R16E tires,
dual 2.5" glasspack exhaust, Z75 quad front shocks, Class IV 12000 lbs GTWR trailer receiver, headlight relays, CB and Ham Radio.
----------
2019 Chevy 1.6L TurboDiesel Equinox LT AWD
----------
Allis-Chalmers CA, Case 530CK Loader/Backhoe with 188D 3.1L N/A Diesel engine, Eager Beaver 5 ton dual axle trailer, MEP002a Onan Diesel generator
Offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Diesel Place : Chevrolet and GMC Diesel Truck Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

PLEASE READ! You must check your email inbox for the confirmation link to complete registration. Please check your spam box if you do not see the email in your inbox.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:
Insurance
Please select your insurance company (Optional)

Log-in


Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Air cleaner legendman 6.2L Diesel Engine 5 06-07-2011 02:20 PM
does any one have a k47 air cleaner used assassin 6.5L Diesel Engine 2 12-16-2010 11:07 AM
Intake Cleaner?? MY06DURAMAX Duramax Third Generation: 2006-2007.5 (LBZ & LLY) 5 10-04-2010 05:47 PM
No air cleaner? bowtieboy Second Generation Duramax Electronics/Tuners 14 12-01-2004 03:54 PM
afe air cleaner adam Second Generation Duramax Electronics/Tuners 11 05-18-2004 05:01 PM


All times are GMT -4. The time now is 05:11 PM.


Powered by vBulletin® Version 3.8.8
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
SEO by vBSEO 3.6.1
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
Shoutbox provided by vBShout v6.2.1 (Lite) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd. Runs best on HiVelocity Hosting.
© AutoGuide