For Everyone That May Want to Make There Own Intake. This Should Help - Chevy Cobalt Forum / Cobalt Reviews / Cobalt SS / Cobalt Parts
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post #1 of 225 (permalink) Old 07-14-2009, 05:24 AM Thread Starter
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For Everyone That May Want to Make There Own Intake. This Should Help

PARTS LIST:

For Aluminum
#9405 MAF adapter
#8219 Universal Aluminum Kit
#9499 90 degree elbow tube
#8132 P4 Cone filter
#9332 Silicone Coupler
For Plastic
#8208 Universal Kit
#8698 90 Degree Elbow
Same filter, and coupler
and you have to cut your own maf adapter
There are some accesories you can get to like a heat shield, and a bracket kit is IMO a must to hold your kit still, and some small hose clamps. All of it comes to about 80-90 dollars

#9405 MAF adapter
#8219 Universal Aluminum Kit
#9499 90 degree elbow tube
#8132 P4 Cone filter
#9332 Silicone Coupler




Before I begin. I will follow up this post with pictures on how to piece it together and where i made cuts with the dremel to help. Now that thats out the way here we go.

Oh and im not making this a colorful post with underlines and neon colors. Just a regular post.


Just go to Advanced Auto Parts/Oreily's/Auto Zone and ask them for the parts to make a intake. They will try and sell you a kit that has you build a model at first. Its more of a design/how it will look in the car. Dont buy that kit. Just buy the parts and filter. It should have a basic kit in a box already. Its just the basic 3 part curve. You will have to buy about 3 more parts and then the filter. All averaging about 80 85 dollars.

***Also you will have to buy the tool to tighten each part. It's like one of those star key tools. Its about 4 inch long if that and small. Its to tighten the clamps around each intake part.***

Once you buy the kit, depending on if they made the piece that holds the Air Flow Sensor, You will have to dremel a slot horizontally down near the filter. Don't do it to big/wide or you will have to fill it to keep excess air from getting in and escaping. When i did mine i kept tweeking it until i could force it down in.

I have no extra air coming in or out. Trust me if you don't do this your check engine light will come on but don't freak out it will go away once the system resets.

After you have the air flow sensor on you will have to put the rubber connector in the middle of 2 intake parts. Fasten it down on both sides. Then put the rest of the intake parts together. Just shape the intake however you want. Then tighten the clamps with that Star shaped 4 inch tool.

Once you dremel and place the sensor in you can finally put your intake on. Now on the Engine where the opening is where you initially connect the intake there is a trick that you will have to do.

Take your dremmel and make 4 cuts into the intake at the base of the last piece. You are asking me why i know. This will ensure that once you use the screw on clamp that once you start to tighten this will cause those pieces that you cut to start to bend and secure themelves against your engine. This will keep any extra air getting into the engine.

Once you've tightened it to your engine just connect your rubber hose from your intake to your engine and you have a completed custom intake.

Oh This intake is completely paintable so you can get a good finished smooth paint job on it to match your color of your car or leave it chrome.

*****ON ANOTHER NOTE I'M NOT AT ALL SAYING THIS IS BETTER THEN ANYONE ELSES INTAKE....I'M JUST GIVING A CHEAPER WAY TO HAVE A CLOSE IF NOT SIMILAR PERFORMANCE TO ANY OTHER INTAKE.......THANK YOU*****

Last edited by TwistedBalt; 10-04-2010 at 04:50 AM.
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post #2 of 225 (permalink) Old 07-14-2009, 05:27 AM Thread Starter
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Here is the video I posted earlier about my intake and how it looks











Here are pics from Slobalt. He went out and did what i did and he seems happy overall.






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post #3 of 225 (permalink) Old 07-14-2009, 11:53 AM
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Looks good! Way to go on that. Where are you feeling gains?
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post #4 of 225 (permalink) Old 07-14-2009, 11:57 AM Thread Starter
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HP increased. IT gets up quicker and Gas improved. Also it got louder.
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post #5 of 225 (permalink) Old 07-14-2009, 11:59 AM
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looks good. its a lot cheaper this route too.

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post #6 of 225 (permalink) Old 07-14-2009, 12:03 PM Thread Starter
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Oh yea Saved a bunch on it .
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post #7 of 225 (permalink) Old 07-14-2009, 02:12 PM
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does it work with SAI?



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post #8 of 225 (permalink) Old 07-14-2009, 02:19 PM
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I love this thing it is way easy to do and cheap. I used spectre parts.


Overall you should have,

a 90 degree, a 45 degree and 3 straights. of course all of the couplings to put them together or the ones they come with are fine. also youll need 2 hose clamps i believe 5/8 inch ones to attach the small hose. youll also need to cut the MAF sensor part in that is really only the real creative part but just use your head youll be fine. Then buy whatever filter you want.

Twisted I also hung mine a little clever as well with the bracket that came with it.

If I get time I will take mine apart and put it back together I guess :( argh.

Last edited by slobalt; 07-14-2009 at 02:27 PM.
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post #9 of 225 (permalink) Old 07-14-2009, 05:48 PM
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Awesome write up TwistedBalt! Looks freakin good man! Unfortunately when I went to the auto store to pick up the build your own kit they had already closed. Missed em by just a few minutes. Oh well! Gettin one this weekend instead.
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post #10 of 225 (permalink) Old 07-14-2009, 06:57 PM
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My kit came as allen wrench screws not torque screws... "Also you will have to buy the tool to tighten each part. It's like one of those star key tools. Its about 4 inch long if that and small. Its to tighten the clamps around each intake part"


Doing a how to on this is hard because I would rather not take my intake apart just to put it back together. If someone wants to send me the money I will buy everything, make the dremel cut and everything and do a how to with that one...

Last edited by slobalt; 07-14-2009 at 07:06 PM.
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