Volant CAI Mod

[4mudder]

There are a few of us with Volant CAI who are unhappy with the amount of engine heat the box allows into the engine. Here is a simple cheap mod to fix that.

First, the weatherstrip that came with the kit was intended to be used on the opening with the intake tube/MAF sensor. I chose to put mine on the fenderwell opening to truly seal off the box to the fender.
Looks like this; note the seal of the box to the fender and the gaping hole by the intake tube...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod001.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod002.jpg

To seal off the forward facing opening I used a rubber cap. I got it at Home Depot, about 4 bucks and it comes with a clamp!
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod003.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod004.jpg

Installation takes about 10 seconds and the final product looks like this...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod005.jpg

While at Home Depot, I also got a 12"x18" sheet of galvanized steel for the other opening, also about 4 bucks.
I measured a trapezoidal shape that closely matched the profile of the box and cut it out using tin snips. Measurements I used are; top=10", front (rad side)=8", back (firewall side) 7", bottom=approx 10.5". I then mocked it up to the box to ensure fitment.
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod006.jpg

While mocked up, I traced the inside to locate the opening on the metal...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod007.jpg

I then centered the MAF tube on the opening and traced the new smaller MAF tube opening which will be cut out...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod008.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod009.jpg

I cut it out using a Dremel tool and test fit... Don't forget to deburr the cut...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod010.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod011.jpg

I had some leftover sound dampening material which I cut to the same size as my plate and cut out the opening as well. I cut the opening in the sound dampener about a 1/4" smaller than the plate so I could wrap the inside of the cutout with foil reinforced butyl for a tighter fit...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod012.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod013.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod015.jpg

Test fit is nice and snug now...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod017.jpg

Attached the plate to the box using 4 screws...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod018.jpg

View from inside...
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod020.jpg

All buttoned up and ready to go with nothing but cold air from the fenderwell!!!
http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod021.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Volant%20CAI%20Mod/VolantCAImod022.jpg

[mole177]

nice work!

i wonder how much it affects air temp.

[4mudder]

I think it reduced air temps quite a bit. My SOTP dyno tells me I picked up 20-25 HP by doing this mod.:jester: :jester:

[07 Elephant]

Chris nice fix. Looks like it should do the trick. If not at least everything fits togeter better. With the addition of the SOTP dyno it sounds like you have one heck of garage setup for the rest of the planned mods. ;P

[Jeremy]

Nice mod 4mudder. I too have thie CAI kit but mine is sitting in my garage. What a POS this kit is from the factory. Maybe Ill look into some of your mods. Do you notice a decrease in noise with your mods?

[4mudder]

Do you notice a decrease in noise with your mods?

Funny you should ask... I thought there might be a decrease in intake noise when I was sealing everything off... and there is. It's not much, but the intake honk seems to be mellowed out a little. At cruising I can't hear the intake at all.
All joking aside, the truck seems a little peppier and I'm hoping for a slight increase in MPG. I need to do some more driving for comparison.

[ligboozer]

Nice work and thanks for the write up. Keep us posted on the mileage numbers, I am looking into this mod as well. I am having a hard time convincing myself to puchase a 300 dollar intake that still needs work to be its most effective though.

[Cash Money]

Nice write up man. Its sad that a company like Volant didn't do this from the get go.

[4mudder]

Its sad that a company like Volant didn't do this from the get go.

Yeah, I was a little surprised and disappointed that the kit Volant sent me just didn't seem to fit or seal that well. I noticed after installation that the intake pipe actually angled DOWN from the throttle body to the CAI box. That didn't seem right and the little piece of weather strip didn't really change or seal anything. That's why I installed it between the fender and the box, at least it seals there.

Then, I got the body lift (1.5"). That straightened out the intake pipe angle and now it runs straight across from TB to CAI. I'm not going to bust on Volant, I kinda like doing the mods, makes them "my own".

[T?@\7]

i was just looking at the volant site and looking at the difference between taco and runners setup..... well on their site the taco intake has this hole (in front) already capped. I wonder if all their newer kits come with that plug or if just the taco? I think im gonna go to HD later and pick one of these up, fck that big hole!

[4mudder]

Yeah, I took a look at their site. That capped Taco box was new. Look at the bright side, for 4 bucks you can "upgrade" to the new design. I think you'll notice a difference, I did.

[4mudder]

UPDATE;
There is definitely more power after I did this mod. Low rpm response has improved (more torque?). I'm not roasting tires, but it is noticeable.
Mileage has improved from low 16s to mid 17s in town driving (50 mph and less) and from low 17s to high 18s on the highway (55-75 mph)
Some of the buzziness in the intake noise has gone away on part throttle acceleration.
Very happy so far.
:drink:

[T?@\7]

I did it too, i think its worth all $4. It seems effective, maybe just placebo :)? But no it does make sense to me that It SHOULD be getting consistently cooler air now. However ive noticed since that my truck seems to like to stay in OD or hesitate between shifting gears (from 3 -> 4 i think).... but I may just need to clean my MAF and filter which I want to do anyways...

**Edit** my shifting woes were due to two frozen front calipers :\