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How to make a "CAI" into a Ram Air TCAI for 40$

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Cheeto6182, Mar 26, 2010.

  1. Mar 26, 2010 at 9:26 AM
    #1
    Cheeto6182

    Cheeto6182 [OP] Cheeto

    Joined:
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    First Name:
    Sean G
    Denver, Colorado
    Vehicle:
    05 Tacoma TRD Offroad DoubleCab
    JBA Headers, Custom Snorkel/Ram-Air Intake, Spal Electric Fan Conversion, TBS lol, Borla Exhaust, ToyTec Coilovers, Old Man Emu Rear Leafs, Bilstein 5100's, Alpine system (type R's), 4.56 Gearing, 285/75/R16, Bead Lock Rims, Bed Carpeting, SoftTopper, Ram Air intake Mod, URD MAF, Dash Dyno, One Piece Drive-Shaft Conversion, Bed Cubby Led Lights, 12,500 Lbs winch, Expediation bed racking system, Hella Lights, Custom front winch bumper
    I have an AirAid CAI that wasn't really a TCAI because the incoming air/filter was still within the engine compartment. After looking at a few ram air set ups I figured I could make mine for less money. For now I wanted to keep the stock air box because I have the URD MAF that is programmed for it. Eliminating that airbox required a re-tune.

    Tools
    1: Grinder
    2: Screwdriver
    3: Drill

    Parts
    1: 3 inch exhaust pipe (14.00$)
    2: One 3 inch air duct bracket from home depot (2.99$)
    3: One Spectra intake mounting plate from Checkers (5.99$)
    4: One Spectra intake tube coupler from Checkers (7.99$)
    5: Spray pain (2.99)
    6: One flexible duct from from home depot (5.00$)
    7: Six self tapping screws (2.00$)

    Procedure:
    1: Remove Grill
    2: Cut a square out of the sheet metal next to the radiator
    2: Take your flexible ducting and mock up where you want the pipe to go. This way you can take it to an exhaust shop and they can use it as a template for your permanent piping. When making your mock up put the grill back on so you can make sure it lines up with the middle slot on the grill.
    3: Go to an exhaust shop with a six pack of beer, bullshit with the one who looks like a beer drinker, talk about manly stuff, make a friend, go home with your custom shaped intake.
    4: Put the intake tube where it will go (if you haven't already cut the tube to size/length this is when you'll do it) and mock up your bracket and air duct plate. My bracket was too big for the pipe so I used some weather stripping I had around to snug up the fit. This turned out to be a plus because it eliminates any possible squeaking from the metal to metal contact on the pipe/bracket. Eventually I will put a nicer bracket in though.
    5: Cut out your scoop from the front of the pipe. I had the shop bend out the end of the tube so it would work like a slide for the air.
    6: Mark where your bracket and intake duct will go. I didn't have a hole cutter bit, this is why I got the air duct plate. It's easy to cut a square out with a grinder. For the bracket and duct plate screws I drilled a guide hole with the smallest bit I had so the self taping screws wouldn't walk on me when it came time to mount.
    7: Mount your air duct bracket and put your coupler on it. Mock up one more time to make sure everything is Kosher.
    8: Paint
    9: remount/assemble and replace grill

    Now I have a ram air true cold air intake. The downside to this set up is the AirAid is not a sealed box, but that can/will be changed soon. All it will take is some sheet metal.
    I'll also go to a plumbing supply store aka home depot and get a plug for the pipe so I can close it during bad weather and not suck up the elements.

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  2. Mar 26, 2010 at 9:35 AM
    #2
    Cheeto6182

    Cheeto6182 [OP] Cheeto

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    Sean G
    Denver, Colorado
    Vehicle:
    05 Tacoma TRD Offroad DoubleCab
    JBA Headers, Custom Snorkel/Ram-Air Intake, Spal Electric Fan Conversion, TBS lol, Borla Exhaust, ToyTec Coilovers, Old Man Emu Rear Leafs, Bilstein 5100's, Alpine system (type R's), 4.56 Gearing, 285/75/R16, Bead Lock Rims, Bed Carpeting, SoftTopper, Ram Air intake Mod, URD MAF, Dash Dyno, One Piece Drive-Shaft Conversion, Bed Cubby Led Lights, 12,500 Lbs winch, Expediation bed racking system, Hella Lights, Custom front winch bumper
    forgot the engine compartment one

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  3. Mar 26, 2010 at 10:07 AM
    #3
    CopDoctor

    CopDoctor Well-Known Member

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    BMS Intake, JB4 chip, Plastidip everywhere
    looks sweet man!! great idea and great job!!
     
  4. Mar 26, 2010 at 10:11 AM
    #4
    Anathollo

    Anathollo www.saveadane.org

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    Cool! Yeah you're going to want to have a cap for the rain. Thats why people are having a lot of problem with the URD true cold air intake.
    +Rep to you.
     
  5. Mar 26, 2010 at 10:45 AM
    #5
    Tacofanatic05'

    Tacofanatic05' #1 Member

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    Hunter
    Waynesville/Charlotte,NC
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    05' Tacoma 4x4 sr5, 3 Inch lift
    16'' American Racing wheels, 285/75/16 Cooper Discoverer St tires, Bilstein 5100 w/eibach coils, K&N Cold Air Intake, Flowmaster Super 44, 1 in 2 out exhaust. Tractor Supply Tool Box, No Mud Flaps, Mossy Oak Seat Covers, Oakley Decals, Hoyt Decal, Window tint 20% on sides 5% on top front windshield, Uniden Cb, and Window Deflectors.
    great idea and great job fabricating
     
  6. Mar 26, 2010 at 11:01 AM
    #6
    Cheeto6182

    Cheeto6182 [OP] Cheeto

    Joined:
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    Sean G
    Denver, Colorado
    Vehicle:
    05 Tacoma TRD Offroad DoubleCab
    JBA Headers, Custom Snorkel/Ram-Air Intake, Spal Electric Fan Conversion, TBS lol, Borla Exhaust, ToyTec Coilovers, Old Man Emu Rear Leafs, Bilstein 5100's, Alpine system (type R's), 4.56 Gearing, 285/75/R16, Bead Lock Rims, Bed Carpeting, SoftTopper, Ram Air intake Mod, URD MAF, Dash Dyno, One Piece Drive-Shaft Conversion, Bed Cubby Led Lights, 12,500 Lbs winch, Expediation bed racking system, Hella Lights, Custom front winch bumper
    In the name of science I went out and got a wireless thermostat with a remote sensor. I mounted the sensor on the wall away from the engine with some thick double sided foam tape that I am hoping provides some insulation from the metal so I measure the air temp and not the metal's. I cruised up and down the same stretch of street, first with the pipe clogged, then with it open. I'm not sure about the quality/accuracy of this thermostat but there is definitely a difference here. Check out the pics, the "out" temp is where the sensor is in the intake. The "in" temp in the temperature inside my truck with all windows down.

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  7. Mar 26, 2010 at 11:10 AM
    #7
    Cheeto6182

    Cheeto6182 [OP] Cheeto

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    Sean G
    Denver, Colorado
    Vehicle:
    05 Tacoma TRD Offroad DoubleCab
    JBA Headers, Custom Snorkel/Ram-Air Intake, Spal Electric Fan Conversion, TBS lol, Borla Exhaust, ToyTec Coilovers, Old Man Emu Rear Leafs, Bilstein 5100's, Alpine system (type R's), 4.56 Gearing, 285/75/R16, Bead Lock Rims, Bed Carpeting, SoftTopper, Ram Air intake Mod, URD MAF, Dash Dyno, One Piece Drive-Shaft Conversion, Bed Cubby Led Lights, 12,500 Lbs winch, Expediation bed racking system, Hella Lights, Custom front winch bumper
    Yea my issue with the URD CAI was the outside filter, I live in Boulder Colorado and there is a lot of snow mud in my grill after a long drive. During Winter this can just be closed =)
     
  8. Mar 26, 2010 at 8:16 PM
    #8
    mgrande

    mgrande iKill

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    Kings, AP 3" leaf pack, timbrens front and rear, TC UCA's, pro comp 7189's, baja ATZ's, CBI sliders and rear, relentless front, dynomax catback
    Looks great man!
     
  9. Mar 26, 2010 at 9:13 PM
    #9
    sp8ed2010

    sp8ed2010 Well-Known Member

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    prob not the best idea for the colorado elements. Like the idea though and nice job.
     
  10. Apr 4, 2010 at 8:51 PM
    #10
    08pretaco

    08pretaco Almost there

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    did you get the idea from empire performance and offroad? im in the process of my custom Cold Air Intake :D
     
  11. Apr 5, 2010 at 5:15 AM
    #11
    Cheeto6182

    Cheeto6182 [OP] Cheeto

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    Sean G
    Denver, Colorado
    Vehicle:
    05 Tacoma TRD Offroad DoubleCab
    JBA Headers, Custom Snorkel/Ram-Air Intake, Spal Electric Fan Conversion, TBS lol, Borla Exhaust, ToyTec Coilovers, Old Man Emu Rear Leafs, Bilstein 5100's, Alpine system (type R's), 4.56 Gearing, 285/75/R16, Bead Lock Rims, Bed Carpeting, SoftTopper, Ram Air intake Mod, URD MAF, Dash Dyno, One Piece Drive-Shaft Conversion, Bed Cubby Led Lights, 12,500 Lbs winch, Expediation bed racking system, Hella Lights, Custom front winch bumper
    I was looking at getting the URD TCAI but didn't want snow and mud of Colorado winter roads getting directly to the air filter. I built a cover for it similar to the deck-plate mod so its not always open. The design just kinda evolved on its own lol Good luck with your CAI!
     
  12. Apr 5, 2010 at 6:05 AM
    #12
    Wattapunk

    Wattapunk Stay lifted my friends !

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    Great job!. I am brainstorming, figuring a way to make a ram air for my hood scoop but having difficulty of trying to figure a way to prevent water from going in. I'll keep searching..
     
  13. Apr 5, 2010 at 6:13 AM
    #13
    Lurkin

    Lurkin Well-Known Member

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    Be careful with this idea. Where the scoop is located on the stock sport hood is not a high air pressure area as the scoop is not high enough (or forward or back enough). If you plumb the scoop and keep the stock fender intake area plumbed, I would expect that the air will flow from the high pressure fender area OUT through the scoop. This will scavage intake air, not ram it.

    Again, just speaking from a thought concept here, haven't tried it myself.
     
  14. Apr 5, 2010 at 6:26 AM
    #14
    Wattapunk

    Wattapunk Stay lifted my friends !

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    After researching some forums here, looks like its not going to work. Due to tacoma's aerodynamics, air travels over the scoop. Oh well, maybe I can make the scoop blow bubbles..
     
  15. Apr 5, 2010 at 6:29 AM
    #15
    Jigzor

    Jigzor Well-Known Member

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    Not to rain on your parade, but it's no Subaru. Same reason as stated above.
     
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