6637 Cold Air Box
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From: Houston, TX
6637 Cold Air Box
Has anyone built a cold air box for the 6637 filter?
I am thinkin about designing one. Possibly havin multiple inlets to the box, one to the front of the truck (ie zoodad mod or something similar) and one to the side of the truck. I seem to remember someone had installed a vent near the badges on the quarter panels.
Possibly building it out of a combination of materials, thin plywood, pvc, aluminum, etc.
Thoughts?
WB
I am thinkin about designing one. Possibly havin multiple inlets to the box, one to the front of the truck (ie zoodad mod or something similar) and one to the side of the truck. I seem to remember someone had installed a vent near the badges on the quarter panels.
Possibly building it out of a combination of materials, thin plywood, pvc, aluminum, etc.
Thoughts?
WB
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Joined: May 2007
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From: Florida
i was thinking the similar thing... could be real nice maybe even try using the orginal equipment box that came with the truck and cuttin it up to make it work the way you want then to make it nice fiberglass everything together would look pretty sweet!
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From: North of Greenville
Due to the possibility of moisture under the hood, I would avoid plywood unless you're talking about reallly thin "project" type stuff that you're going to fiberglass completely (which is my plan right now).
I'm personally toying with some thoughts slong the path of switching over to the Donaldson PowerCore filtration media, and installing TWO filters instead of one, each one being the new Volant replacement for the 6637 in terms of size. This is going to require me to relocate the battery, for one thing. Another part of my plan is to have an opening to the fender well that comes into the box through a diffusion/distribution plate. Another feature I plan to build in is a large cold air inlet plenum that includes a 9-inch or 10-inch, 800-1200 cfm electric fan that pulls in the cold air by force. With the open fender well access, any excess air will simply be blown through without pressurizing the inlet to the turbo. Plenty of design work left for now, but these are my thoughts for what I am planning.
Others have built sheet metal barrier plates that isolate the 6637 much like a volant system does, so you're not on the wrong track by any means.
I'm personally toying with some thoughts slong the path of switching over to the Donaldson PowerCore filtration media, and installing TWO filters instead of one, each one being the new Volant replacement for the 6637 in terms of size. This is going to require me to relocate the battery, for one thing. Another part of my plan is to have an opening to the fender well that comes into the box through a diffusion/distribution plate. Another feature I plan to build in is a large cold air inlet plenum that includes a 9-inch or 10-inch, 800-1200 cfm electric fan that pulls in the cold air by force. With the open fender well access, any excess air will simply be blown through without pressurizing the inlet to the turbo. Plenty of design work left for now, but these are my thoughts for what I am planning.
Others have built sheet metal barrier plates that isolate the 6637 much like a volant system does, so you're not on the wrong track by any means.
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I am with you! We are finishing a complete line of universal products based on the Powercore. We are entering Off Road Racing in a big way. They demand all different kinds of conigurations. We will have universal air boxes, T's,Y's, 45's, 90's, different lenght tubes in different diamaters. We are also running the Powercore with a flange on each end so it becomes an inline filter.
More to come.
More to come.
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From: Houston, TX
I was thinkin using the thin plywood for the actual body and aluminum stove ducting for the plumbing of the air inlets, with a good coat of fiberglass and paint to weather proof it and make it look good.
Not sure what to make a side vent out of....
Not sure what to make a side vent out of....
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Hotshot
Joined: Nov 2006
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From: North of Greenville
Pat... I don't want to use a leaf blower for two reasons... its larger size compared to the small low-profile fans I can get, and the need for converting the voltage over to A/C for it to run. Besides, I can get one of these low profile fans for less money anyway (I think).
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Joined: Feb 2007
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From: Sterling Heights,Mi
Tell me what you are looking for, if you can wait until Monday, and i will find something for you..The problem so far though, I can not find anything that puts out more then 750cfm in a dc fan in that diameter. But I will continue to look if you wanted.
Last edited by just another truck; Sep 20, 2007 at 01:25 PM.
Post Fiend
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From: White Mnt's,New Hampshire
you know I told a couple of guys a few months ago I would pull my AFE stage 2 box out and make a template with it..maybe I should do this this weekend...it seals to the under liner under the hood..keeps the heat out..it also lets you get air from the fender well all the way around to the radiator...im sure there is room to make this thing wider to fit the 6637 into it..
Post Fiend
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From: Millbrook Alabama
Originally Posted by just another truck
pete, why not a leaf blower?? sorry Gene
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From: North of Greenville
HA! I new that earlier post would bring you out of hiding, Brandon. It was about the time that you put together that rather unique arrangement that I was beginning to formulate my idea mentioned above.
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From: Dallas-Ft. Worth
Originally Posted by ron's power stoke
you know I told a couple of guys a few months ago I would pull my AFE stage 2 box out and make a template with it..maybe I should do this this weekend...it seals to the under liner under the hood..keeps the heat out..it also lets you get air from the fender well all the way around to the radiator...im sure there is room to make this thing wider to fit the 6637 into it...
Joe
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From: White Mnt's,New Hampshire
Originally Posted by Izzy351
That would be an excellent start, for sure. It probably would have to be worked just a bit to get the 6637 in there at the correct angle, but the hard parts would be done. Let us know if you get to it!!
Joe
Joe
thanks izzy...I think ill have time this weekend to do that..I been wanting to test my boots' plenums and turbo for leaks since the turbo up grade..at least the height and the bottom plate would be all made with the bolt holes already marked..just need to make it a bit wider...ill see what I can come up with and start a new thread on it..how far away from the fender well is needed to make a snug fit for the 6637 ??? does it need to go all the way out to the driver side IC pipe??
Hotshot
Joined: Nov 2006
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From: North of Greenville
Originally Posted by just another truck
Tell me what you are looking for, if you can wait until Monday, and i will find something for you..The problem so far though, I can not find anything that puts out more then 750cfm in a dc fan in that diameter. But I will continue to look if you wanted.
http://www.performancecenter.com/pro...ns&universal=0
http://www.performancecenter.com/pro...ns&universal=0
http://haydenauto.com/products/electric-fans.htm
There are also several sellers on eBay where some of these fans can be had for $50-$70.
Since the Donaldson Powercore filter replacement for the 6637 is not yet available, I'm biding my time and thinking through the whole project. Overall, it's going to cost me $200 for the two filters (guaranteed for 4 years each), probably near that again for relocating both my batteries, then another $100 in miscellaneous supplies for fabbing and mounting the intake box housing, then another $50-$100 for the fan, and probably another $50 for controls because I'll probably try to get fancy with it and have a variable speed fan that operates based on engine load. Overall, I expect the project to run into about $600-$650, which I don't have handy right now anyway... but i have time to plan and design.
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