Like I said, nothing fit quite right. My original plan had been to use the PFS intake without the box and fashion a new cold air shroud that used the PFS intake box backing plate as the base. I wanted to replicate the cold air intakes that scavenged air from between the radiator and the chassis. Alas this was not to be as even with the box removed from the PFS intake the backing plate still interfered with the IC. Options? M2 carbon fiber or CWR carbon fiber? M2 was backlogged 3 months (surprised?) so I ordered the CWR intake and have no regrets. Part of the issue with the PFS intake is that is "steals" air from the IC duct. As far as packaging goes this makes sense but from a performance standpoint it is questionable. That in addition to the fact that the tube feeding the intake box is a measly 2.75" in diameter which is feeding two 2.5" intake pipes. I wonder what is the restriction with this setup? So the cold air intakes which get air from beside the radiator seem to be the best approach..if it can be packaged nicely enough. M2 and CWR seem to have accomplished this. Read on....

The first step was to remove the radiator flange. Should have done this with the radiator out of the car. This was of course after I realized a modified PFS intake wasn't going to work. And I was NOT going to drain the coolant system and pull the radiator out AGAIN! Note also the missing cross member bolt. In order to get the CAI (cold air intake) box to sit low enough to clear the hood this bolt had to be removed, a hole drilled in the bottom of the box and the bolt reinstalled. Worked out pretty well as the CAI box is now quite securely mounted.

Where all the cold air intakes get their air from - alongside the radiator. I measured the opening at approx. 1.25" x 15" for a hole size x-sectional area of 18.75 sq-in. Compare this to the PFS intake x-over tube size of 2.75" diameter for a hole size x-sectional area of 8.6 sq-in.

CWR intake box from the side. Lots of Carbon Fiber - it weighs next to nothing. And looks pretty good too.

A problem. Nah...Really? With the CAI box sitting all the way to the rear the OE lower turbo supply hose was not going to fit. Solution: pull it through the hole in the box and shorten the supplied aluminum connector pipe.

View of the lower turbo hose fed through the lower hole in the intake box.

Picture of the lower filter fitted. I had to cut the supplied aluminum connector almost in half to get the lower filter to sit forward enough to allow proper positioning of the upper filter. It's a tight fit in there but it works. I also trimmed about 1/4" of rubber off the end of the filter hose.

Everything else with the CAI fit fairly well with one more exception. The hoses from the dreaded stock air pump were a difficulty. I decided to take the PFS route and "T" in two lines and forgo using the lower drivers side "upper" main pipe bung and simply put a rubber cap on it. The solution is not pictured here as I was still pondering what to do.

CWR cold air intake installed and complete - minus the air pump "T" and lid of course. I still need to find a better air pump "T" to replace the copper unit I used for a while. YUCK. Found one! After walking the aisles of Home Depot a bit more I found the perfect "T"...problem solved.

Another angle of the filters.

As is the case with our cars cooling is everything. Properly ducting and sealing of the radiator is crucial to maintaining cool temperatures. So in order to seal the radiator sides a I fabricated a shield/seal for the drivers side to replace the old one - the radiator now sits lower. The only problem was with the AC evaporator relocated one of the old clips is no longer functional.

So I figured out how to maintain use of the AST but now had to run the plumbing. The results of my effort. Lots of new clips and brackets to keep the hoses in place and some creative house routing. Such things as PCV grommets, holes for new clips, etc. etc. were needed and duely fabricated. In short if a bracket was removed due to clearance problems I made a new one that would fit, if a bracket was needed to secure a line or hose I'd make one of those too. Zip ties are great but IMO should be used only when necessary.

The lower AST drain hose was fed through the frame rail using an angled PCV valve grommet. The hole already existed in the cross member - no drilling or cutting required. It would not have been possible to feed it behind the rail as then it would be at risk for hitting the eccentric shaft pulley and it was not possible to feed it in front of the frame rail as the IC would sit on it.

An interesting note: While I had all the hoses "out" I noticed that the coolant reservoir overflow hose is not one piece of hose but in fact three! These three lengths are then connected with slip on extensions. No clamp, no nothing. And mine came off very easily. So a few zip ties and they are sure to provide a good seal now, meaning my cooling system will stay full.

To see if how the IC would fit with the new CAI I threw everything together (without the K&N filters). There was lots of room. I also took the opportunity to put the temporary IC feed pipe together - sorta. An aluminum pipe will be fabricated to complete the project when all is up and running again.

Another angle. Again my desire was to reuse the couplers from the PFS "kit" I had but of course these 2.75" couplers were just a hair too short. Three feet of red silicon coupler material was purchased and cut to length accordingly.

Another angle. Getting closer to completion.

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For Day One of the CWR install effort

For Day Two of the CWR install effort

For Day Three of the CWR install effort

For Day Five of the CWR install effort

For Day Six of the CWR install effort

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TRIPLE-R MAIN PAGE
GENERAL OVERVIEW | THE HEART OF THE BEAST | STOPPING AND TURNING | THE COMFORT ZONE

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7-UP CLUB MAIN
OUR "LOCAL7" COMMUNITY | THE WORLD OF THE RX-7

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If you would like to contact me and converse about my experiences with my 7:
please feel free to send an e-mail to rotarypower@rx-7.net

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This page last updated April 22, 2002

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Disclaimer: All images contained on this page are the sole property of C. Regan