Dodge Owner Forums

Dodge Trucks => DIY & Self Help => Cummins DIY's => Topic started by: NickBeek on March 19, 2009, 02:34:10 am

Title: Making a 2nd Gen Intake Horn Fit a 3rd Gen
Post by: NickBeek on March 19, 2009, 02:34:10 am

Ok here are some pics. 1st how I cut it, the piece on the left is the stock piece, the pieces on the right are what I did to it to get it to fit decent with a 2nd gen intake horn. I was going to cut it on the bottom straight section, but there are raised letters molded into the plastic and I didn't want a sealing issue so I cut it on the top section. I didn't remove any length, just cut it in half, so a boot could give it some articulation. Then I test fit it and found out I needed to remove some off the bottom end to get the parts to meet closer.

(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0140.jpg)

Here is a shot of the horn
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0141.jpg)

I started by installing the boot at the intercooler.

(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0142.jpg)
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0143.jpg)

Then I installed the bottom section of the tube. I left everything loose until it was all fit.
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0144.jpg)

Then I installed the top piece of the tube with the top boot.
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0145.jpg)

It was then time for the last boot.
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0146.jpg)

I buttoned it all up by starting at the CAC boot clamp, and worked my way up to the top. I had to make sure on the modified ends of the tube that I didn't have the ends too far into the boot. You want to only go as far as the flat section of the boot end inside.
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0147.jpg)

It lined up pretty good and is a hell of lot better then it was. I'll get on it a little bit tomorrow and see if it blows off under boost. :taz:

BTW, here is the difference between the two intake horns. 1st the stock 3rd gen.
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0120.jpg)

Stock Second Gen.
(http://i39.photobucket.com/albums/e189/NickBeek/IMG_0121.jpg)

As you can see, the second gen intake has a larger opening so that the engine can breath better. I got this part used on one of the other forums I visit for under $30 shipped to the house. I figured I would try this out before I spent upwards of $300 on an aftermarket unit. I have read, but not been able to confirm on a dyno that this mod will net an extra 30 HP. While that is a bit of a stretch in my mind, it has to flow better by virtue of sheer volume. If I get a chance to dyno I will post back the results.

Title: Re: Making a 2nd Gen Intake Horn Fit a 3rd Gen
Post by: Kilch123 on March 19, 2009, 02:48:49 am

Good job Nick!

Title: Re: Making a 2nd Gen Intake Horn Fit a 3rd Gen
Post by: NickBeek on March 19, 2009, 03:06:21 am

Thanks Kilch.

Title: Re: Making a 2nd Gen Intake Horn Fit a 3rd Gen
Post by: Kilch123 on March 19, 2009, 03:09:43 am

So, this is just a 3rd gen tube, cut, with an extra boot? Or did you need other parts?

Title: Re: Making a 2nd Gen Intake Horn Fit a 3rd Gen
Post by: NickBeek on March 19, 2009, 04:17:53 am

You are correct, it is a stock tube that I cut and added another stock boot to.

Title: Re: Making a 2nd Gen Intake Horn Fit a 3rd Gen
Post by: FroneDaddy on March 19, 2009, 02:01:15 pm

Nice write up Nick! :up:

Glad 'ya got the DIY post figured out :lol:

Title: Re: Making a 2nd Gen Intake Horn Fit a 3rd Gen
Post by: 04cumminsram on June 15, 2009, 03:08:00 am

congrats sir