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Custom Cold Air Intake
for a 4.0litre 6 cylinder Falcon

The whole assembly is pretty much straight forward. U need 3" stainless steel piping, a POD of your choice
(K&N is quite suitable) and a custom heatshield.

The stainless stell piping is a 3 piece mendrel bend piping neatly welded together with a 110 degree bend in order to limit restriction. The heat schield is made of tin, due to the fact it is light, cheap and easy to work with if you have only limited tools. Otherwise u can use and sort of material u prefer, just make sure that it does not heat up very easily. Tin has the characteristics not to heat up easily.

This is the unit assembled. U can see that i left a small gab in the heat schield, which is as u can see in later pictures, air is getting forced through the front bar into that heatshield. I wanted to give the air the opportunity to escape if the pressure builds up too much (some of yous probably think u idiot now, u can feed even more air into it, but trust me this is already pushing more than enough air for the time being).

Thats the area where the air box used to sit, i removed it completely to the bend and drilled a 4" while in the red area. That connects directly to the front bar, which you can see in the next pciture. Be careful as u drill through there, because there is the airbag sensor sitting directly below it. The POD will stick to 50% in that hohle, which means it is to 50% in the front bar.

Thats my front bar and POD sits in that left hohle next to the spottie. I used to have mesh there but i just bought bigger mesh and i havent fitted it yet.

And this is the unit completely fitted. The heatshield is screwed to the chassy, to hold the piping up is use a normal drainpipe holder for 50 cents from the hardware house. This assembly together with a complete exhaust system & Tickford ECU upgrade gave me 17kW @ wheels gain.



NOTE: This system has been designed for an AU Falcon. It can be used for EF and EL Falcons, but that requires small changes to the piping. The volume of the pipe is exactly the same as the volume of the previous air intake, which means that the ECU had easy going on readjusting to the new flow parameters and did not require a chip.

Hi there,
the names scott. i was just reading your article on the air intake thing for flacons where you were saying that the pipe and the airflow is exactly the same. byt putting the manderl pipe in there you have managed to emiminate the restrictor which is directly at the end of the airbox thus changing the rate of airlfow into the intake manifold, im not here to correct you more to ask for advice.... do u thing putting the pod filter doen there and loosinf the exterior air through the gap in the bonnet would slow the flow of the air?? does it get good flow with the pod filter down there.