Cold Air Feed with Almera Airbox

Hi all!
I am going to design a cold air feed for Mikey (my 1.0 K11) using a GA16 airbox I have ordered. I am going to make a duct from the fog light blank on the passenger side, cut through the inner arch liner and come from under the battery tray and join the airbox. I am going to design and cut a custom blanking plate which is the same shape as the fog light surround but houses an intake opening. This should be a decent cold air intake as it is in direct airflow and will incorporate the larger airbox.
My question: What size is the intake hole on the GA16 airbox, as I need to know for a ducting pipe.
Any tips or possible upgrades I could do alongside this, let me know!
Thanks, Jak.

*will post update photos on my project [HASHTAG]#MikeyTheMicra[/HASHTAG] thread.
 

LiamC

I've ruined my car 🙁
That piece sticking out of the airbox will be your biggest bottle neck in terms of airflow, but yeah it's around 73mm outside
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Update time!
The carbon canister needs to be lowered in such a way that the Almera airbox sits level, otherwise it rattles and can crush the breather hoses.
To get around this, I found the simplest way was to just turn the bracket upside down and replace the cc the right way up, as then the canister can be lowered right out of the way. Simple!

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The airbox now goes on with a new rubber seal over the throttle body from Nissan. The end of the box is cable tied on at the moment as the bracket mounting points on the N15 are different to the K11, but it does the job!! the hose was from ebay, and was £12 for 2m. You need approx 1.3m to reach the hose with my route. Again, cable ties to the rescue, but I have some stainless steel hose clamps on the way!
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To direct the hose to the foglight hole, the wheelarch liner needs a little bit of trimming. The main article (the one that goes all the way around) only needs an inch off of the edge closest to the inner wing at the front. The small panel at the back needs a bit more. When the car is jacked up, draw a mark following the wheel arch liner on the small plastic panel. When removed, cut around an inch further in from that mark. Excuse my unneatness, but I just wanted it on!
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The hose was routed from the airbox down behind the battery. It goes beside the gearbox where the earth wire is. It then comes out where your plastic has been cut and then pull it to the foglight hole!
Mine is not yet held in place by the foglight hole but here it is at the moment.
Once properly secured I will give another update!

Cost so far:

Airbox - ~£20
Hose (2m) - £12
Cam cover breather filter - £4.99
Hose clamps (yet to arrive) - £1.99

Total: £38.98
Much cheaper than an induction kit!!
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DEdgeMac

Buy & Sell Member
To direct air directly in the feed and to finish off the look more cleanly I'd personally use a fog blank and cut it to incorporate the hose.
 
To direct air directly in the feed and to finish off the look more cleanly I'd personally use a fog blank and cut it to incorporate the hose.
Funnily enough, that's what I'm planning to do! 😂 the problem is the hose is 71mm in diameter, but the inside of the foglight blank maxes out at 68mm, so the hose would either come out as an oval, would be slightly covered by the blank or the outside of the blank would also need cutting. I'm going to go for the first one, so it comes out as an oval shape. 😁 thanks anyway, though. Great minds think alike, and all that!😂🤣
 
Thought of a mesh cover? Or a flange
Just been so low and at the front it may suck a lot of debris
I have lots of mesh left over from the grills I made, and I was going to incorporate some into the foglight blank when it is adapted for the duct. Like you say, it's very low, so gets a lot of debris thrown at it!😊
 

SuperUno

Buy & Sell Member
Nice to see some proper work going on here, but once this dry weather ends (please do soon!). You may want to move it up. One deep puddle or a ford, and it will be new engine time, they don't like the fact that water can't be compressed...
 
Nice to see some proper work going on here, but once this dry weather ends (please do soon!). You may want to move it up. One deep puddle or a ford, and it will be new engine time, they don't like the fact that water can't be compressed...
Thanks! I only use the car for autotests at the moment as I'm 16, so can't take him on the road yet! When I start using him for rallies etc. I may move the duct to the grills in the bonnet just as a bit of a safety precaution.
Thanks for the advice!

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Another update!
The foglight blank has been used as a mounting for the hose. It was marked out using some card shaped as the hose opening and a marker pen.
A dremel with a small cutting disc was used to cut through the (surprisingly soft) plastic. A hacksaw blade was used to cut the centre part as the dremel wouldn't reach.
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The wheel was removed again as part of the inner arch had started to rub where it wasn't cut correctly. It was removed and further cut so a trim clip could hold it in place. The tape was there to see if it rubbed which thankfully, it didn't.
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A spare piece of leftover mesh was cut to the shape of the fog light blank, and is held in place with 5 self-tapping screws. Simple yet effective.
With the wheel arch liner removed, the hose was threaded into the blank snugly and siliconed around it to make sure it doesn't move. The foglight blank was pushed in place, the wheel arch liners refitted and then it's done!!
Let me know what you think!
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Questions - Is there a noticeable improvement? Also doesn't the ribbed tubing result in more turbulent airflow which is bad?
I've not driven him yet since, but it is noticeably louder and a deeper tone, even with a standard paper filter.
If the car doesn't feel any different or feels worse, then the hose would be changed to a silicone tube bent the same. I'm unsure at the moment but it doesn't seem to run worse at any revs.
It is only an inexpensive fix to the restrictive intake, so if it doesn't work then it can always be improved. 😊
I'll let you know how it feels once I've driven him.
 

LiamC

I've ruined my car 🙁
A spare piece of leftover mesh was cut to the shape of the fog light blank, and is held in place with 5 self-tapping screws. Simple yet effective.
With the wheel arch liner removed, the hose was threaded into the blank snugly and siliconed around it to make sure it doesn't move. The foglight blank was pushed in place, the wheel arch liners refitted and then it's done!!
Let me know what you think! View attachment 58114View attachment 58115View attachment 58116

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Good to see the airbox found a good home, it looks to be a well designed intake you have done there too, let us know how it goes

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