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So I've seen multiple posts in forums online about the airbox being restrictive and people cut a hole in it, usually very sloppily, and they claim to get a little boost in fuel economy and smoother acceleration. I hadn't done it yet because it seems to me that I'd just be sucking hot under hood air in.

So, I made a little duct to get past the hot under hood air and get cool fresh air from the outside. It's was a cool CAD project because of the funny shape hole that I made and the fact that I had to follow one of the ribs down on the outside so I did not have a 90% corner. Also I added ribs to the inside of it to give it more rigidity since the walls are thin, 2mm. It took 7.5 hours to print since I used ASA for strength and heat resistance and slowed the print head way down to get better layer line adhesion. I also printed it laying down so there was a whole damn forest of tree supports!!

I made my hole more neatly than others I've seen

The Part

Brought it into the box like the factory one

Bridging the gap to get out of the hot engine bay

Sticks out right behind the headlight

So I've seen multiple posts in forums online about the [airbox](https://poal.co/static/images/d9e9696913a60c99.jpg) being restrictive and people cut a hole in it, usually very sloppily, and they claim to get a little boost in fuel economy and smoother acceleration. I hadn't done it yet because it seems to me that I'd just be sucking hot under hood air in. So, I made a little duct to get past the hot under hood air and get cool fresh air from the outside. It's was a cool CAD project because of the funny shape hole that I made and the fact that I had to follow one of the ribs down on the outside so I did not have a 90% corner. Also I added ribs to the inside of it to give it more rigidity since the walls are thin, 2mm. It took 7.5 hours to print since I used ASA for strength and heat resistance and slowed the print head way down to get better layer line adhesion. I also printed it laying down so there was a whole damn forest of tree supports!! [I made my hole more neatly than others I've seen](https://poal.co/static/images/61011313c38f9e3e.jpg) [The Part](https://poal.co/static/images/3e87e6c5c7c7475f.jpg) [Brought it into the box like the factory one](https://poal.co/static/images/2f2b7323687c7bd6.jpg) [Bridging the gap to get out of the hot engine bay](https://poal.co/static/images/89783711b1b4b664.jpg) [Sticks out right behind the headlight](https://poal.co/static/images/6c6c752d6f777644.jpg)
[–] 1 pt

Interesting mod. What year truck?

[–] 1 pt

Could've used a piece of pvc pipe and a hole saw too.

I can't wait for metal 3d printers to be more realistic in price. Then you could 3d print some awesome mods. Looking at you compound turbos.

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I could have, but that would have been very boring.

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Does the 3d printer have its own modeling software or do you use a standalone cad program then import? Looking for a 3d program where I can do the function of 3d autocad without the $250 a month subscription...

[–] 1 pt

I use FreeCad. It's a great cad program and free.

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A open cone filter is cheaper and works better.

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Science says otherwise.

[–] 0 pt

Bring receipts. The primary function of the air box is to hold the filter. The secondary function is to dampen the intake noise that is created.

Nothing about the engineering of standard air boxes on non performance vehicles was done for performance.

Now if you can use White person speak and articulate that the engine bay heat can be an issue in open filters, I’d have given you some credit, but that is why most systems isolate it with the back of the grill/air entry point then develop a partition for the open filter. Then there is zero restriction based on a shit plastic box.

This logic was proven on all the shit box forigens and many American sedans back in the 90’s.

Also if you go look at the engineering documents from Gale Banks on their system you find similar outcomes.

Manufactures don’t engineer for performance outside of a few platforms. It’s for sound reduction.

Also a side note even hot or warm air is better than reduced air. If you move more air then it has to suck more from somewhere that isn’t warm (as engine bay)

[–] 0 pt (edited )

The Science (dieselarmy.com)

Also, you kind of made my point:

>Nothing about the engineering of standard air boxes on non performance vehicles was done for performance.

Hence the modification to bring in more cool outside air.

Perhaps you misunderstood.

Lab studies on turbo-diesel engines confirm that lowering intake air temperature (via better sourcing or cooling) increases air density, improves volumetric efficiency, and can reduce fuel consumption by around 1% (when cooling power is accounted for), with benefits to emissions and efficiency. That, according to Sciencedirect.com