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Good morning, I was just going to post a thread on what I've done to my 05 6.0L. Upon taking the grill off, I couldn't for the life of me determine the best amount of air getting to the airfilter with the fiberglass board in front of the "boot". SO, I took a drill, and hacksaw and cut a "sizeable" hole for direct airflow into the air boot-airfilter. I checked/rechecked, after I put the grill on that it is in an area fairly protected so it wouldn't need a filter screen, as I have the TRex billet grill insert. Also the hole basically resides at the vertical and crossbar (chrome) intersection. I can't really tell seat of the pants whether its done any good, but it hasn't hurt anything for sure.
Wix has teamed up with visteon on a new air filter system. It is going to take the place of the old bulky air filter, but instead of the big filter it is going to have a pannel filter that only takes 5 minutes to change. There is a new plastic intake that is made to fit where theold system is. They claim a higher efficency, more capacity, and more air flow. And the best part is that the filter is going to cost around a third of the price.
It's about a 4-5" oval. Drilled a bunch of holes to make the circle, then cut and sanded the oval into a nice smooth "factory" looking hole with a Dremel.
Be careful with the ZOODAD and the snorkle that is attached to the front of the airfilter. I found that during a rain storm that water will be sucked into the front of the airfilter through the ZOODAD and snorkle. I decided to make my own "Po-Boy intake" by cutting off the snorkle that is on the front of the airfilter. I now have a HUGE hole that lets the truck breathe as deep as it needs to when I get on the pedal. Did my HP/TQ go up? If the OEM filter is as good as they say, my HP/TQ gain is not as much as the AFE II, but then I didn't spend that much either to get whatever it added.
Good point about rain having direct access to the filter. There were problems with snow entering the housing too that required a deflector kit on previous year models. I like the ideas of just taking the front cover off but that might let in hot air from the engine compartment. What would be ideal is a cold air inlet system that draws air into the air box from below the bumper that has a few bends to trap water and let it drain off.
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