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Discussion Starter · #1 ·
As I wrote in a couple of previous post, I've been experimenting with making my own CAI, first attempt was met with some unfavorable results (poor idle quality) After taking Pete's advise (from Ford Chip) and doing some more research on-line, my second attempt was very successful. Yesterday the final version was put together and installed, the best thing that made it work so well was actually moving the MAF sensor housing directly behind the cone air filter. My old PiperCross filter uses a power flow cone inside the housing to straigten the air flow through a 2.75 inch taper right into the MAF sensor. At this location the MAF is approxiately 1.5 feet away from the Throttle body and clocked to the factory position at a 45 degree angle. As for the performance, "Outstanding" is the best description, unreal throttle response from idle all the way to redline and a definate power increase from 2300 to 4700 rpm with a great induction sound in that same power band. I made two MAF sensor housing during the process, the first one was made out of the one available from Pep Boys in which I had to file out the original sensor hole and elongate it to accomodate the flat sensor found on the Fusion as well as the supplied adaptors.The second was made out of a sectio of aluminium tube stock with a block of alluminium tig welded and milled out to accept the senor. The second version is much more involved but the original plastic housing works just as well. Hopefully the picture will transmit OK
http://putfile.com/pic.php?pic=2/4916145394.jpg&s=x4
 

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Very good looking job! I am impressed! I am interested to know if it has changed your MPG in any way. I live in such a restrictive State that you have to show a CARB sticker for anything to pass emissions.

Keep Going,Your doing Good! :blue:
 

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Discussion Starter · #3 ·
[quote author=Cross Bolt link=topic=40323.msg586615#msg586615 date=1140391076]
   Very good looking job! I am impressed! I am interested to know if it has changed your MPG in any way. I live in such a restrictive State that you have to show a CARB sticker for anything to pass emissions.

   Keep Going,Your doing Good! :blue:
[/quote]

Thanks for the encouragement and compliment, the emissions part I haven't thought that one out yet but in Virginia their not as strict with compliance testing. As for the MPG improvement I'll write a follow up at the end of the week but at this point It'll most likely be worse with my right foot in it more for a while. :cheers:
 

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Was that for a 4cyl or 6??
 

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Wow! That is the cleanest prototype! Very nice, do you plan to do any dyno or since this 1 worked out/ How about for a v6? Very nice! :shock:
 

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Discussion Starter · #8 ·
[quote author=revspeed702 link=topic=40323.msg588493#msg588493 date=1140501550]
Wow! That is the cleanest prototype! Very nice, do you plan to do any dyno or since this 1 worked out/ How about for a v6? Very nice! :shock:
[/quote]
If I had a V-6 to look at and get some reference information I'd probaly give it a stab and see what could be fitted in the space. Maybe I'll get a hold of someone at the plant here and take a look. As for the MAF housing, I'm fairly sure that the 3.0 takes the same flat sensor and could be used as I did for the I4. More later....
 

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Discussion Starter · #9 ·
[quote author=SELectivesurgery link=topic=40323.msg588621#msg588621 date=1140521132]
how many bends are in that thing? I'm sure it did wonders for performance, but wouldn't you get better performance out of a straight shot?
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I wondered the same thing, but placing the MAF housing directly behind the cone filter the intake signal across the sensor acts like a short ram tube. Everything behind that sensor is just air volume that is available for comsumption through vacume draw of the throttle body. The other concern with this setup was air stacking up in the long tube but so far idle quality has been rock solid.
 

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Excellent. Looks good.

I am curious about the MAF housing you mentioned from Pep Boys. Did you buy the housing and sensor or just a housing???
 

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Discussion Starter · #11 ·
[quote author=pete link=topic=40323.msg601735#msg601735 date=1141325873]
Excellent. Looks good.

I am curious about the MAF housing you mentioned from Pep Boys. Did you buy the housing and sensor or just a housing???
[/quote]

Pete, It was just the housing with the factory sensor. It just took a little filling and fitting to get the right size slot in both the housing and the supplied adaptor. There are 3 adaptors in the package, I practiced on 2 of them and used the one supplied that only had a small tube hole and sealed it with an O-ring. The milled out housing I made looks allot better, but the prototype one worked just as well.
 
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