Windstar Intake Clearance - Hitting Hood

[FarFire70]

Move the hole you cut down lower and further to the passenger side. And you need the rubber insert that everyone forgets at the junkyard.

Mine from 2014 the day I did it. It doesn't hit the hood.
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I had seen your previous posts in my planning and thought I came down far enough to be on top of the grounding nut. I didn't realized you sent through the spot welds.

I think to go with a new hole or grinding this one is really opening a new layer to the project. It's a good fallback option. I think I'll try a short extension mentioned above.

—-

Interestingly, my local used parts dealer (we don't have a good selection of U-Pull-It spots around me anymore) just gave me the rubber insert/snorkel for free when I stopped and tried to source one from another used parts dealer in his network.

That didn't come through so I ordered a used one off eBay - and it didn't come with the rubber insert — so the 2 trips/purchases got me the full Windstar setup...

 

[FarFire70]

@FarFire70 To fix this problem, pop rivet a patch panel over most of the hole. Then redrill it further down and over. Use my pic of the ground bolt and the overlapping seam as a reference. You new hole cuts through that seam and the bottom is below the bolt.

And before you do anything, go back and get the rubber insert. Use that to determine the size hole saw you need to use. My memory says it was 3.25".

Got the insert. You and/or other posts recommended 3-1/8" hole saw and it was a perfect size.

Patch panel isn't a terrible idea. I'm back and forth on that or using a spacer.

@Wildman posted this over in my build thread and could help push the intake back enough (hopefully)

https://www.amazon.com/Spectre-Performance-8148-Mounting-Plate/dp/B000BPUTL4/?tag=wranglerorg-20

 

[Rubiconned]

That's interesting. It's a Specter, but it doesn't have the hood that keeps rain from going in.


The original Specter kit had it:

 

[Wildman]

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That's interesting. It's a Specter, but it doesn't have the hood that keeps rain from going in.


The original Specter kit had it:

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@NashvilleTJ made his own.

Post# 1880 over in his build thread on JeepForum

https://www.jeepforum.com/threads/nashville-tjs-coilover-build.3838225/page-94#replies

 

[FarFire70]

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That's interesting. It's a Specter, but it doesn't have the hood that keeps rain from going in.


The original Specter kit had it:

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Was this a Specter kit for TJ 4.0?

@Wildman and @NashvilleTJ talk at lot on Specter as they build out V8 (Hemi, Magnum, etc?). So I'm familiar with Specter as a name but haven't dug in on parts.

Not ready to toss the Windstar — but very curious what you posted, if built for the TJ-specifically as I like continued interested from companies on the TJ-specific market.

 

[Rubiconned]

Was this a Specter kit for TJ 4.0?

Yes. But I haven't installed it yet.

 

[NashvilleTJ]

Nothing is actually *attached* to the firewall. It just goes through it. There is a velocity stack on the other side which is bigger than the hole so it stays put.

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By the way - very cool cabin filter.

 

[FarFire70]

I know that I was thinking the extension may be the only way. I'm thinking maybe the filler plate and a redrill may also be a good option.

I'm still thinking through how I approached that.

On a separate note, how has everybody with a Windstar intake dealt with the heavier air intake pulling down on the intake tube? Mine currently rides on the throttle body cables.

Maybe a new angle for the filter box resolves this, but I unlikely.

I worry about the sharp edges of the clamp. Thinking I need a brace, which I haven't seen others using this intake address or express concern about.

 

[inkedrose]

This is mine with a Hemi swap. The air filter housing is from Spectre & the hoses are from a few different vendors. But the same principle. Sorry to derail your thread for a minute.

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THOR makes a kit to do it with. They put the air filter inside the cowl.

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https://trailheadoffroad.com/product/wrangler-tj-lj-cowl-intake-97-06/

Every time I see posts about your build I'm blown away. So far out of my skill set but damn is it cool! I love the sound of a big nasty V8

 

[Wildman]

I know that I was thinking the extension may be the only way. I'm thinking maybe the filler plate and a redrill may also be a good option.

I'm still thinking through how I approached that.

On a separate note, how has everybody with a Windstar intake dealt with the heavier air intake pulling down on the intake tube? Mine currently rides on the throttle body cables.

View attachment 552703

Maybe a new angle for the filter box resolves this, but I unlikely.

I worry about the sharp edges of the clamp. Thinking I need a brace, which I haven't seen others using this intake address or express concern about.

If you were able to use a short flex tubing that say moved the air filter housing back 1.5-2" would that put it in a better spot where it wasn't sitting on things? Or where you could fab up some sort of support bracket? Just spit balling here. I know I had to move things around some before I came up with a solution to support mine. And if you go read when Jeff did his he came up with a unique solution to support his air cleaner housing.

You've got some good options now. Lay things out mocked up as best as you can and figure out which one works better for you.

Every time I see posts about your build I'm blown away. So far out of my skill set but damn is it cool! I love the sound of a big nasty V8

Thank you. There are times I think it's above my skill set too. The forum and help from here and friends normally gets me through it.

Yes a nasty V-8 just sounds wicked.

 

[JMT]

Yes a nasty V-8 HEMI just sounds wicked.

FIFY

 

[Wildman]

FIFY

The Magnum sounded pretty wicked too, but if I'm being honest the Hemi does sound better.
I can't wait to drive it and see the difference.

 

[JMT]

The Magnum sounded pretty wicked too, but if I'm being honest the Hemi does sound better.
I can't wait to drive it and see the difference.

I agree! I looked at your thread yesterday and was three pages behind. When I saw @Sj's TJ sugggest you fire it up I scrolled past you and Trev’s discussion super fast so I could find the video! Excited for you. A few easy things to go! Glad that oil leak was an easy fix. VROOOOM VVROOOOOM….

 

[Wildman]

I agree! I looked at your thread yesterday and was three pages behind. When I saw @Sj's TJ sugggest you fire it up I scrolled past you and Trev’s discussion super fast so I could find the video! Excited for you. A few easy things to go! Glad that oil leak was an easy fix. VROOOOM VVROOOOOM….

Well I'm not sure just how easy some of the issues are going to be..... Dropping the fuel tank is a process.

 

[FarFire70]

If you were able to use a short flex tubing that say moved the air filter housing back 1.5-2" would that put it in a better spot where it wasn't sitting on things? Or where you could fab up some sort of support bracket? Just spit balling here. I know I had to move things around some before I came up with a solution to support mine. And if you go read when Jeff did his he came up with a unique solution to support his air cleaner housing.

That's what I'm thinking if I go with spacing it back - maybe 2" or so. I don't know that I need much.

That also helps for if I lift the rear to get it off the cabling — and yes, supporting brackets have been in my head as a need since I installed the air intake...

You've got some good options now. Lay things out mocked up as best as you can and figure out which one works better for you.

You're 100% correct and this has been a great thread of ideas! I appreciate everyone's input. Mock-up is the next step for sure!

 

[GTTJ]

What's this piece and where would I get it? I assume it's not part of the windstar system. There's a windstar at the upullit yard near me that i might go check out tomorrow.

 

[jjvw]

What's this piece and where would I get it? I assume it's not part of the windstar system. There's a windstar at the upullit yard near me that i might go check out tomorrow.

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Silicone 90° elbow. I have no recollection of the sizes from ten years ago. Take measurements and look here...

https://www.siliconeintakes.com/

 

[FarFire70]

What's this piece and where would I get it? I assume it's not part of the windstar system. There's a windstar at the upullit yard near me that i might go check out tomorrow.

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https://www.amazon.com/gp/product/B0BZ8DL6NS/?tag=wranglerorg-20

 

[FarFire70]

Silicone 90° elbow. I have no recollection of the sizes from ten years ago. Take measurements and look here...

https://www.siliconeintakes.com/

You documented it well back then I did just f'up the firewall hole that I now need to solve.

 

[jjvw]

https://www.amazon.com/gp/product/B0BZ8DL6NS/?tag=wranglerorg-20

That listing is lying. That is not a T-bolt clamp in the picture.

Two T-bolt clamps will cost more than that elbow.