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Discussion Starter #1
Being frustrated with the fact that none of the Saab tuning companies would step up and design a "cold Air Intake"(CAI), I figured I'd just design one myself. For those that don't know what a CAI is, it is a cone filter type set up where the filter is routed down in to the fender/bumper area to grab cooler air.

Below you will see the CAI I developed and installed in my 2000 Viggen. Note the 2 aluminum cast elbow, these I had cast to my specs (designed on Pro-E) to allow proper fitment at a metal foundry. The remaining piping is mandrel bend stainless steel. All connectors are high temp silicon and all clamps are stainless steel T-bolt type. Filter of course is K&N. Piping is 3" thru-out for really nice flow.

For the first batch of elbows I had cast, I have gotten enough to make 10 CAIs. I'm working on sourcing the other parts at bulk discount to complete the 10 additional kits.

I will then be selling these kits. I'm also working on completing the detailed install instructions (w/ pics) to include with the kit.



What do you all think? Any intertest in the kits? I've only installed this on a 9-3 Viggen, so I'm not 100% sure it'll fit a normal 9-3 T7 (2000-2003)...not sure if the same space is these in the bumper area.



Pics below:














 

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I propose an experiment: On the first really rainy day, drive at highway speeds on a busy freeway for an hour or so and see if you can monitor voltage across your MAF. With all the water spray, also see if there are any fluctuations in A/F mix.
 

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intakes mounted as low as yours on a rainy day are horrible ideas, good luck with that... i think that is the reasson companies dont make intakes with filters mounted that low... u know how much water u r gonna suck up???:roll:

now if u were to mount the filter right after that bend at the maf sensor so it would sit right in the opening, that would b a good idea.


also y r there no brackets to hold the intake in place, vibration kills maf sensors..... write that down
 

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Discussion Starter #4
mike saunders said:
I propose an experiment: On the first really rainy day, drive at highway speeds on a busy freeway for an hour or so and see if you can monitor voltage across your MAF. With all the water spray, also see if there are any fluctuations in A/F mix.
Got the K&N DryCharge Filter Wrap just for that! :cheesy:


My brother's CAI on his 1.8T GTI and my buddies SRT4 Neon CAI intakes both have this and had no problems over the rainy season.
 

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Discussion Starter #5 (Edited)
ricot83 said:
intakes mounted as low as yours on a rainy day are horrible ideas, good luck with that... i think that is the reasson companies dont make intakes with filters mounted that low... u know how much water u r gonna suck up???:roll:

now if u were to mount the filter right after that bend at the maf sensor so it would sit right in the opening, that would b a good idea.


also y r there no brackets to hold the intake in place, vibration kills maf sensors..... write that down
Looks lower in the pics than it actually is. Its actually higher than my brothers 1.8T GTI kit and my buddies SRT4 kit.....I'm not worried one bit.

As for the braket....I've got the 120 lb zip tie there just for that, but its such a perfect, tight fit, I can full force try to move it and doesn't move one bit.
 

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ok but like i said i would like to have one that mounts the filter right in front of that hole i am talking about.
 

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Discussion Starter #7 (Edited)
ricot83 said:
ok but like i said i would like to have one that mounts the filter right in front of that hole i am talking about.
IMO there is not enough room with the head light there to mount a filter with a 6" base. I went thru about 10 different designs and this one is perfect fit.

On another note....funny all the negativity right off the bat...and we wonder why there's nearly nothing out there for Saabs compared to say our VeeDub 1.8T buddies.:roll:
 

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u call it negativity??? i call it constructive criticism... that is how products evolve and get better... trust me i have researched intakes for t7 i have 3 different designs i have tried, i don't like to use that stock rubber connector because it sucks, that is y my intake is the way it is. i am gettin a new heatshield in the next couple weeks so that should be good.

Go over to VwVortex and then come back and talk to me about negativity... dont ***** about how companies dont make intakes a certain way or this and that, they spend money and research safe ways to make their parts and use them... If companies made intakes like yours they would get a lot of customers complaining about blwon turbos, cracked pipes, blown maf sensors.... etc....
 

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Discussion Starter #9 (Edited)
ricot83 said:
u call it negativity??? i call it constructive criticism... that is how products evolve and get better... trust me i have researched intakes for t7 i have 3 different designs i have tried, i don't like to use that stock rubber connector because it sucks, that is y my intake is the way it is. i am gettin a new heatshield in the next couple weeks so that should be good.

Go over to VwVortex and then come back and talk to me about negativity... dont ***** about how companies dont make intakes a certain way or this and that, they spend money and research safe ways to make their parts and use them... If companies made intakes like yours they would get a lot of customers complaining about blwon turbos, cracked pipes, blown maf sensors.... etc....
Ouch, rico...was just makin' an observation from a lot of stuff I've read on many Saab forums. I'm well aware of vortex...was quite the dubber back in the day (www.watercooled.com/all_motor)

"If companies made intakes like yours they would get a lot of customers complaining about blwon turbos, cracked pipes, blown maf sensors.... etc..."

Come on man, how on earth can you make a statement about my intake when you've never even seen it in person. I've been running this thing for 2 months, purposely going thru puddles, etc to ensure its able to hold up. Look at the materials I've used, this thing is stout and probably an overkill, but that how I do things. "blwon turbos, cracked pipes, blown maf sensors"...not quite sure how an airfilter can blow a turbo or maf sensor....but I hear ya on those who make questionable products.

Its cool not to like it.....I was going for a factory, classy, clean look (hence using the rubber boot and the black (verses blue or red) connectors. Been trying to source a 45 degree 3" to 2" reducer in black to replace the stock boot, but that'd have to be custom made and it isn't the cheapest thing to do. So to keep this thing cost effective, I decided to go with the stock boot.
 

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jperk said:
IMO there is not enough room with the head light there to mount a filter with a 6" base. I went thru about 10 different designs and this one is perfect fit.

On another note....funny all the negativity right off the bat...and we wonder why there's nearly nothing out there for Saabs compared to say our VeeDub 1.8T buddies.:roll:
Dude, there's no negativity at all....

Just offering some suggestions that might spur business. If you said, "I've tested this for two months during Cali's wettest spring in decades and here are my results...," people would seriously flood your inbox with requests! :D

I don't see anything wrong with your design, in fact, it's pretty damn sweet. The only question I have is the ease of filter maintenance, which will be critical since you've put the filter in the dirty, wet airstream, instead of bringing the airstream to the filter. Will users need to unscrew the plastic undercarriage air deflector to get at the filter, or can it be removed from the top?
 

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meh, hes right ricot take it easy, theres no need to be that harsh.

I hate the black rubber piping too, thats why i completely got rid of all of mine. I do have to say though that all of us are really skeptical about intakes, because we've all seen alot of them go bad (especially cold air ones).. so i can understand ricot's concerns. I'd have to see more of your intake and hear more feedback from other people who are willing to run them. If you could update your design to get rid of the black ribbed piping and had smooth pipe right to the turbo that would be fantastic. I have that right now except mine isnt cold air.
 

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Discussion Starter #12
mike saunders said:
Dude, there's no negativity at all....

Just offering some suggestions that might spur business. If you said, "I've tested this for two months during Cali's wettest spring in decades and here are my results...," people would flood your inbox with requests! :D

I don't see anything wrong with your design, and the only question I have is the ease of filter maintenance (which will be critical since you've put the filter in the dirty, wet airstream, instead of bringing the airstream to the filter.) Will users need to unscrew the plastic undercarriage air deflector to get at the filter, or can it be removed from the top?
Yeah, I hear ya....just a little defensive I guess;)
User would only need to unscrew the part of the plastic undercarge right by the filter to pull the filter out (also to install), the whole thing does not need to come off. You will need to jack up the passanger front tire as well
 

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jperk said:
Yeah, I hear ya....just a little defensive I guess;)
User would only need to unscrew the part of the plastic undercarge right by the filter to pull the filter out (also to install), the whole thing does not need to come off. You will need to jack up the passanger front tire as well
Ok...If my memory serves me correctly, that's about six 8mm hex screws, right? And you have to jack up the car.

Can I make a suggestion? (This, too, isn't negative. It's just constructive criticism...) You've taken a 5 minute maintainence job and turned it into a major production. This will make inspecting the filter into a chore, not a routine quick check that someone can do every month or so.

If you ducted the air to the filter, you're still taking in the same cold air but:
* You're minimizing or eliminating the water intrusion problem
* You're cutting down on some of the grit because it won't want to travel up the tube
* You're keeping the filter itself cleaner and maximizing flow (a dirty, clogged air filter cancels all the benefits of cold air)
* You make maintainence a snap because the filter is up in the engine compartment.

Just duct the air, put a heat shroud around the filter and you're golden....
 

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sorry if i came on too strongly, i am also very defensive when epople wanty to sell something, that hasnt been used that often, or that has no info to support that it has been tested. Like mike said if u had stated that u had it on there and drove through puddles blah blah blah then thats a different story, my point with keeping it in the enginebay and right behind the head light like i said before was because it is soooo much easier to check it out and clean it, and u r still getting cold air. U should also think about making a heatshield for the thing, because if it is anything like my intake, it will get hot fast... really fast.

that is all..
 

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you can easily go stage 3 with this setup no problem...





yes, a stock airbox with 3" tubing sucking from below the headlight, and drop-in panel JR or K&N filter is sufficient and some tuners would even tell you this is superior to the cone intakes. :p

although I admire your ambition and creativity I would be worried about the MAF, water, etc... but I must say the fit and finish on your intake looks high quality!:eek: :cool:
 

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Hey guys,..on my Viggen I was wondering if I could modify the airbox. It looks different from my NG900s airbox. What do you remove and how? I'm not even sure where it goes after the tube leaves the box.
 

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Avi, that's the 9-3 airbox above. If you remove the passenger-side headlight, you'll see the intake tube and the half-moon shaped cutout that allows air in from behind the foglight.
 

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And this is present on the Viggen? I see this extra resonator box and I'm not sure what removal entails..if you've got details :)
 

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avi, put up the front of the car pn jackstands and you can get better access... there is a bolt holding the "resonator" box into place. then you just give a good yank.... I have a pic of the box, you can see where there is at least one bolt....with it removed it seems better.... and more sound along with a panel filter. but not as noisy (or nice soudning) as the cone. but I feel this way the air is a bit colder.;)
 
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