[mjewell]

To avoid having any water entering a cold air intake from under the car, angle the opening to the rear. There will be less chance of a large puddle forcing water into the filter.

 

[srt4wannabe]

You can also put in an Air ByPass Valve in the pipe which will protect the system should the filter become submerged in water. Follow this link www.aempower.com
They have them listed there and I am sure the other manufacturers of CAI systems have this sort of part available. If not just measure your intake pipe and order accordingly.

 

[dawm]

I plan on going over to my garage tomorrow to tinker on my 98 R/T, while im there im gonna tinker with the idea since ive got spare couplers and intercooler piping (altho its only 2.5") and see what all needs to be done

 

[Shaun]

I plan on going over to my garage tomorrow to tinker on my 98 R/T, while im there im gonna tinker with the idea since ive got spare couplers and intercooler piping (altho its only 2.5") and see what all needs to be done

I'm very anxious to hear what you come up with! Please let us know if you've got any good ideas.

 

[ShockJock]

With just a few mods this should work.

 

[MykTurk]

You know, as goofy as that looks, I see no reason why it wouldn't work...
Ugly, sure, in a very "Road Warrior-ish" kind of way. Crude but effective low buck application, I see oil lines and a small intercooler in place, yes... I'd say it works!

 

[dawm]

Ok guys, spent a few hours tinkering with the idea and I found a solution i plan on going with once a few things are done that are hindering me using it.

1) i need to get the support bracket welded to the pipe (i don't trust everything hanging off the silicone coupler)
2) the IAT sensor wiring wont reach and I'm not about to solder longer wires to it on my almost new car, but I'm pretty sure i can come up with an extension piece that will plug and play just fine next time i goto the junkyard.
3) Need a port for the PCV/Breather hose (A simple threaded barb fitting a the proper size hole in the pipe will solve that)

BTW I did start and rev the engine a few times after everything was snugged up.. I can't wait to get this officially completed because the car sounded SOOO MUCH BETTER!!

And onto the details...

I had a spare pipe from my K&N Neon SRT-4 CAI that i wasn't using, I cut it up, using the same filter that came with it (K&N RU-4950) and a 90 degree silicone coupler we have a solution that puts the filter directly under the battery but still well above the bottom of the bumper (i forgot to take some reference pictures) in fact its well above the lower core support, so inhaling water is a non-issue unless you drive through a puddle/pond that puts the water level above the lower grille in the bumper. There is also a threaded hole in the lower core support that the support bracket bolts to.

Pictures:





So there we go, a actual CAI for the Caliber (Atleast the Caliber R/T FWD 5spd). You saw it here first

 

[Shaun]

AND THE CROWD GOES WILD!!!!!!!

WOW, it feels like Christmas!
Well Dawm... I've gotta hand it to you. I was about to go with ShockJock's idea, but I think I like yours a little better!
Now, where do I get the parts you've listed? Or can I chop up my K&N and make this work? I'd rather not since I plunked down so much dough on it, but I'll do whatever I gotta do to make this rig work. The only problem with the K&N tubing is it tappers down in size (bigger at the filter, then smaller to the engine).

 

[dawm]

You'd just be better off selling the K&N Intake rather than hacking it up and throwing away the left overs.

Well basically its just the following:
90 degree 2.5" Aluminum pipe (cut down to size)
90 degree 2.5" silicone coupler
Two 2.5" hose clamps (or T-Bolt clamps) - for the 45 degree coupler (one for the TB, one for the pipe)
K&N RU-4950 Filter (But any filter with similar size/shape would work, you can look up specs on knfilters.com)
Hose clamp for the filter

The only additional pieces would be the extension for the IAT sensor wiring, and a support bracket, I tried to locate another spot to help support the piping but I could only come up with the one that requires welding. But looking at the K&N instructions for their intake, it looks like they have a clampable mount that might work if its available to order, basically it sits on the intake and then its gets a hoseclamp over it to hold it in place, then a bracket attaches to it. I sent K&N an email to see if that part was available for purchase by itself.

Everything could be purchased off eBay. I would recommend aluminum piping as it wont ever rust, using steel piping you run the risk of it rusting on the inside due to moisture which even tho its filtered air, moisture is common. I've seen alot of people using steel piping for their intercooler setups only to see them rusted on the inside after a few months of use.

As long as the filter isn't Taller or Wider than the RU-4950 (5.5" Tall, 5" round at the top, 6" round at the base) it wont hit the frame/chassis
http://www.knfilters.com/search/product.aspx?Prod=RU-4950

-------------------------------------------------------------------------------
Heres a few items on ebay that could be used:

180 Degree Intercooler Pipe ~ Cut this in half and trim the length and you have 2 CAI pipes.
http://cgi.ebay.com/ebaymotors/2-5-Universal-Turbo-Intercooler-U-Bend-Pipe-2-5-Inch_W0QQitemZ120292539897QQcmdZViewItem?hash=item120292539897&_trkparms=39%3A1|65%3A1|240%3A1318&_trksid=p4506.c0.m245&timeout=1218834550856
90 degree Silicone Coupler
http://cgi.ebay.com/ebaymotors/_Car-Truck-Parts-Accessories__CXRacing-2-5-Enforced-90-Degree-Elbow-Silicon-Hose_W0QQitemZ250280336851QQadnZCarQ20Q26Q20TruckQ20PartsQ20Q26Q20AccessoriesQQadiZ2865QQcmdZViewItem?hash=item250280336851&_trkparms=39%3A1|65%3A2|240%3A1318&_trksid=p4506.c0.m245
K&N RU-4950 Filter
http://cgi.ebay.com/ebaymotors/K-N-UNIVERSAL-AIR-FILTER-2-5-INLET-L-5-5-RU-4950_W0QQcmdZViewItemQQ_trksidZp1638Q2em118Q2el1247QQcategoryZ33659QQihZ006QQitemZ160272406289QQrdZ1QQsspagenameZWD1V

 

[RavenGhostwolf]

great quick efficient design concept :rep:

 

[Shaun]

Where does the crank case vent hose plug into now? My K&N has a skrew in nipple vent for it to slide over that's up near the filter (just outside the head shield opposite the sensor plug)... Which leads me to question#2 where does the sensor plug into?
Sorry if all my questions sound elementary or self explanitory, but I'm kinda new at this stuff.

 

[dawm]

The sensor wiring doesn't reach, which is problem #2 (Problem #1 is the support bracket needing a weld) Next time i goto the junkyard im gonna see if i can find a male end of the sensor pigtail and make an extension piece (i already have a spare female end off my other project), You could cut and solder longer wires to it, but im not willing to do that as ive only had the car for a week.

Adding a barb to the pipe and a longer hose from the PCV isnt that hard, just drill a hole in the new pipe and thread in a barb fitting. Or get a bung welded on and do the same.

Maybe a vendor on here could come up with a package for this, I've already done the leg work, all that needs to be done is pipe bent, cut to size, weld a breather port & support bracket, solve the IAT wiring issue and bundle it up with the filter and coupler. I can talk to a few people locally and possible get a few of these made but thats iffy at best. The only setback is the IAT wiring not reaching.

 

[Shaun]

I'm going to see a guy about exhaust tomorrow... I'll see if he can help me put this rig together. He's probably got the right tools to do this sort of thing.
I really want to dump my current CAI setup and do this... can't wait!

 

[dawm]

I'm going to see a guy about exhaust tomorrow... I'll see if he can help me put this rig together. He's probably got the right tools to do this sort of thing.
I really want to dump my current CAI setup and do this... can't wait!

An exhaust shop should be able to recreate it just fine, minus the coupler and filter, but i don't know if they'd have aluminum piping, steel would work but as i mentioned before steel has the ability to rust and rust likes to flake off and that totally defeats having the filter on the end of the pipe =p But as i said before the only issue I've yet to solve is the IAT sensor wiring.

 

[Shaun]

I'll probably end up cutting and splicing my sensor wiring. I don't have much choice.... Not only do junkyards in my area not have any Calibers to scrap from... most have never even heard of a Dodge Caliber. I called and asked if they had any Dodge Calibers on their lot and they said "A Dodge caliper... for what car?" DOH!!!
Any drawbacks to splicing the wiring?
Also, I'm not sure what a "barb" or a "bung" are (unless your talking about the human buttocks)... but hopefully my exhaust guy will know.

 

[dawm]

a bung is kinda like a nut you weld to something to give it extra surface for threads.
a barb is that pipe with edges that you put hose on and the edges prevent the hose from easily coming off.
you can get a barb that also has a threaded end so that it screws into the bung.

heres a picture of the type of barb im talking about

and this is a bung

most newer dodges share the same connectors/sensors, you dont need to find a caliber but something newer that is a Chrysler/Dodge might have similar parts/connectors.
You'd be surprised what you can figure out if you poke around cars in the junkyard =p My 98 R/T has a 00 Stratus 2.4 Engine Block, 02 Stratus head, 98 R/T Cams, 04 SRT-4 oil cooler,turbo,oilpan,oilpump,waterpump,intake manifold, 00 Neon Transmission..etc

there's no drawbacks in cutting and extending the wires, if done properly no one would be the wiser, just be sure to heat shrink anything you solder so that it isnt exposed to moisture or cause a short. I'll prolly be extending my wires too if i cant find the connector im looking for. If the connector is found than it makes the whole thing much easier for everyone else and makes it an easy bolt on modification. The IAT issue is why i think there are no other intakes of this style out.

 

[dawm]

Good news.. i think i have found an IAT harness

So guess what that means? aside from having to get a support bracket welded.. this idea is no longer an idea its a reality.

 

[MykTurk]

$12 is not an expensive gamble... Especially if it works! If it doesn't, and you haven't hacked it up, it's still a good part, off to the 'Bay! You may even get more than you paid.

 

[dawm]

Yep, just ordered it from my rapist of a dealer and it will be here next week (special order from NJ) so once i get it ill confirm if it indeed is the proper connectors. And if they are, we'll have ourselves a simple and easy DIY REAL CAI (that someone will steal and make millions on eBay, hopefully they keep the name 'Dawm Style CAI'

 

[Shaun]

Yep, just ordered it from my rapist of a dealer (they charge LIST on everything, but are just down the street compared to the discount dealers which are about 30mins away..) $13.25 and it will be here next week (special order from NJ) so once i get it ill confirm if it indeed is the proper connectors. And if they are, we'll have ourselves a simple and easy DIY REAL CAI (that someone will steal and make millions on eBay, hopefully they keep the name 'Dawm Style CAI'

I'm eager to hear how well it works!
Please keep posting once you get it installed and have some drive time with it, pics would be great too!
I'd love to know if it improves "seat of the pants" acceleration, and most of all... if it's less noisey than the aftermarket CAI's that are out there now... or better yet, how does it compare to the stock air filter sound levels in the cab during acceleration and while driving at speeds of 50-70mph, (which, with my experience, is when the K&N was the LOUDEST!). While others may like it, the K&N is way too loud for my taste. I'm eager for the performance, but not the noise.