1-
http://www.sonicownersforum.com/forum/t1236/ is where the original write up for this DIY so you could use a reference to what I mention on this alternate install.
Buy the same Flexible air intake kit and sink strainer that Danny5 mentioned in his write up.
After purchase these two rubber couplings from home depot:
3in X 2in rubber coupling
3 in. x 2 in. Cast Iron, Plastic, Steel, Copper and Lead to the same, Flexible PVC Coupling-P1056-32 at The Home Depot
3in X 3in rubber coupling
3 in. x 3 in. Cast Iron, Plastic, Steel, Copper and Lead to the same, Flexible PVC Coupling-P1056-33 at The Home Depot
2- I didn’t remove my bumper since I find it a hassle and too many screws to take off so I started by removing my passenger side tire and removed the 4-5 torx fender screws to remove enough of the fender liner to have enough clearance to work with. (you may remove the bumper if you like but im living proof that it can be done through the fender liner)
3- I did not remove the foglight housing since I didn’t want to break the tabs and they were a pain to get loose, I cut out a 3.5in hole with the bumper still attached. (same tool danny5 used in his write up). I did a 3.5in hole to make the metal duct flushed to the foglight housing.
4- I pretty much did the same thing danny5 to eliminate the stock intake pipe BUT cut where the fabric tube meets a plastic component that ends up connecting to the stock air box. (if needed use his pictures as a reference) reason for this was to have a good place to attached the 3in X 2in rubber coupling since the stock intake size is about 1.5in, works like a charm!
5- After eliminating the stock air intake tube, use the 3in X 2in rubber coupling to attach the end of the flexible 3in hose from the intake kit to the plastic tube that was left from the previous step.
6- I primed and painted the metal intake duct from the kit so that it would match my cars color scheme and provide a better corrosion barrier to the metal. At the same time I also cut the ends (the reinforcement piece) of the sink strainer and painted it with gloss black so it’s easier to clean.
7- After they both dried I inserted the sink strainer through the back of the metal duct and bent the ends of the of the sink strainer back and epoxied them to the metal duct. I used black electric tape to make sure that there’s no over overkill on the epoxy to allow the flex hose to still fit over the end of the metal duct.
8- Sand down the hole a bit so it could be smooth instead of rough edged. This is for a clean installation!
9- I attached the metal duct to the flex tube through the foglight housing hole using the 3in rubber coupling. I DIDN’T epoxy the metal duct to the foglight housing since the 3in rubber coupling seals the back of it.
10- Reinstall your fender liner with the 4-5 torx screws. And reinstall your tire. And your done!
Let me know if you have any questions or concerns!!!!
