I wanted to get to this and that throttle body DIY yesterday, but a family thing and awful weather (still ongoing) caused me to postpone it until today (weather cooperated just in time).

This time I worked on the piece that runs through engine bay itself just in front of the Weapon-R pipe with MAF sensor. Previously, a steel piece was was here, but not any more.

Some of you will see some design elements used from previous modifications I have done, including the heat shield, and the use of a smaller pipe inside a larger one to prevent cold air to pass by the section where the hot engine air enters (with the latter being done to prevent engine choking on low idle).

 

First thing we did was take an innocent 5 inch diameter cooking pot as shown.

 

We then traced a 3 inch diameter to start and preceded to bore holes as shown. (this is the long way to do it, but eventually it all worked out).

 

We then cut out the area and had to sand it so it was slightly wider, we'll see why in a second.

 

I had an old rubber piece from the top of an old air filter that I was going to use to attach to the pot, much like my last heat shield, so that I could insert it eventually on to a new PVC tube (which was apparent from the first shot in this thread).

 

Here was the sanding operation on the pot.

 

Eventually we attached the rubber piece to the pot.

 

Now it's time to make the main part of the piece. This will require a 7 inch long piece (just as long as the previous steel piece that as in here). We will be using PVC.

 

Piece being cut and the heat shield attached for clarity on the idea at hand.

 

Next few steps are the real key.

First we cut off the top of a 3-to-2 inch circumference reductor as shown.

 

Now we want this piece to go inside of the 7 inch tube.

 

However, as you note in the picture below, it won't fit...yet.

 

Now I am going to have to make slight incision along the bottom of the reductor (some day reduction) piece.

 

So my cousin Rodrigo proceeds to cut what will actually be about 1.25 inches worth of material in terms of short side width along the bottom of this piece.

 

Now we trim the other side off.