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Thread: How to Drill the airbox

  
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    How to Drill the airbox

    just thought i'd post this up here to help people who might be in my situation in the future!

    unfarmiliar with the new astra engine i didnt know what drilling would do... i was afraid of a tacky noise etc. but this is not the case

    thinking about it logically, your simply making your own custom induction kit - only allowing cool ait intake rather than hot (like a normal induction kit) i found the guide on a corsa forum but same principle applies.


    Welcome to the guide on how to drill you airbox.

    This guide was carried out on a 1.6sport but has also been done on an escort 1.8gti and a 1.4 corsa sport. The basic principles of the guide can be used to drill the airbox on any other car.

    Tools
    Drill
    Drill bits.



    Simply locate your airbox




    take the top of your airbox off and put it somewhere safe. also remove the filter and put this somewhere clean. we need to get the bottom of the airbox out.

    in most cases, remove the chrom clips on the corners to pop the lid off, remove filter and lid, the bottom part of the filter simply pushed towards the headlamps until the two prongs come out of their rubber housing at the far end of the box. dont worry about applying too much energy to remove it, it is fiddly! once the top 2 prongs are out, simply wiggle it out by pulling it in the opposite direction (towards windscreen) another little prong underneath will come out from the opposite direction.




    using your common sense... think about it for a second... imagine the box in your car... only drill on the part of the box which is furthest away from the engine. this way, air is sucked from near the headlamp which tends to be cold. the rest of the airbox (when in place) seperates the hot air from the cool air in your engine bay.



    now simply drill the holes at random. the more or bigger the holes, the louder/deeper your car will growl.



    CAREFUL NOT TO DRILL HIGHER THAN YOUR PANEL FILTER LINE. REMEMBER THAT YOUR DRILLING THE BOTTOM HALF OF THE AIRBOX - BE SURE TO ONLY GO BENEATH THE PANEL FILTER OR YOUR AIR INTAKE WILL SUCK SHIT FROM YOUR ENGINE BAY WHICH COULD PROVE FATAL

    i drilled my box 3 seperate times, putting more holes in each time, then testing it back in place to see how it sounded. my holes are on the bottom of the airbox and on the left side (no higher than where the panel filter goes)

    the more holes the better, with only a few holes, i didnt hear a difference.

    then after the third and final drilling session, i tried it again and was dissappointed that i heard no difference... UNTIL i put the pedal to the floor and it had an amazing roar!

    i was shocked! completely free modification and it makes it growl like a beast. not a tacky sound, just like an induction kit sound... only technically better because it has cool air fed into it rather than hot engine bay air!

    well i hope i've answered most of your questions as these are the questions i wanted answering when i was doing it!

    put your airbox back together again and take it for a spin. you'll notice a performance increase as it pulls you back in your seat too!

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    have you got a vid of it so i can see wat it sounds like ?

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    Follow jam On Twitter
    Oh dear
    Its a jam thing

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    It's still sucking in hot air, albeit diluted with some ambient outside air, but that's the same as an open cone with a cold air feed anyway

    And if your are going to do this use proper hole saws for a tidy job

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    hahaha reminds me of my good old essex boy XR3i days!

    the less said about this mod the better though.

    As long as you're happy

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    I read the thread and left.

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    as said... your still going to suck in hot air buddy..

    good on you for having the balls to destroy ur air box tho..

    as long as ur happy thats what counts
    The coupe...ITS ALIVE & back from the dead....again!
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    i can understand the thought, but i would be scared to loose compression with in the box! Air goes in, air comes out, none for the engine! LOL!

    i think 4 holes would have been ok! Not 44!
    You Can Sleep In Your Car But You Can't race Your House!

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    just to clarify.. the pics are of a corsa and not my astra.. like i did say, i took the how to from a corsa forum.

    i dont like the look of that kids airbox, which is why i have only drilled mine where it cannot be seen cos that does look tacky as hell.

    the location of the holes on the box are near the headlamp only, so when driving and you open the window for a cool breeze, that is what is being passed around the headlamp. im not saying it isolates ice temperatures from engine temps im simply stating that it is a cooler alternative to an induction kit, costs nothing, sounds decent (not too loud, not chavvy, and it only actually makes a sound difference if the pedal is floored), and it allows more air intake on the whole for a slight performance increase as it doesnt have all of the air intake to slow and restrict the air.

    before you mention, i have derestricted the box but lets face it, i free'd about 1mm or so of space in doing so. hardly gonna make a noticeable difference.

    like i mentioned, its only an alternative, lots of people mention it and it took me ages to find a forum which simply shown how its done. as i wasnt confident enough to just have at it so to speak. so i simply posted it on here. if you dont like the idea then thats fine, if like myself your curious with your new motor then simply pick up an airbox from a scrapyard for probs less than a 5er to keep as a spare incase you dont like it.

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    Quote Originally Posted by NickW View Post
    i can understand the thought, but i would be scared to loose compression with in the box! Air goes in, air comes out, none for the engine! LOL!

    i think 4 holes would have been ok! Not 44!
    the engine physically sucks the air in (hense the hissing sound when you tap your pedal to the floor)

    i still have original air intakes in place so all that works as normal (standard air inlet acts as a forced air intake, simply catches air inside it and forces it thru to the filter as you drive. so it is getting the same amount of oxygen intake, only it has more of a selection so to speak to suck in more oxygen with less resistance, causing smoother acceleration and quicker response.

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