DIY Cowl intake for Jeep XJ 4.0 (Cool and cheap)

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Some guys been cooking this one up for a few months! Looking to free up space in your engine bay? Raise the water pickup height? Decrease the temp of intake air? Want all these things on your Jeep Cherokee XJ?
Well do we have a project for you! A cowl intake moves the pickup point from in the engine bay to the cowl (firewall) by cutting over the crank case to the passenger side of the vehicle. Often an issue with this build is deciding how to filter the air as most common filter wont fit in the space of the cowl. Go to K&N.com and order this filter directly for recreating this yourself! (You can find the filter Model by watching the video)
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27 июл 2024

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Комментарии : 70

@corbinfrazier9019 2 года назад

i like how you fab'd that cowl cover. no welding, super simple. When I DIY "upgrades" it usually doesn't look like how you did it, clean job.

@SomeGuyOutside 2 года назад

Thank you!! Necessity is the mother of innovation, I’ve been teaching myself to weld but my harbor freight welder (and my skills) are far from capable of doing aluminum yet and I think rivets look cool/are quite easy to work with!

@mamatronic963 2 года назад

Classic xj owner - performance on a budget - great bank for your buck

@richtyler1353 2 года назад

Great job looks fantastic. Awesome video thank you

@berkeleytrue 2 месяца назад

I had used PVC tube between an air cooler and the manifold in a supercharged mr2. It started melting traveling over the sierra. Definitely would use something with a higher temp rating.

@jasonhaner2319 Год назад

The old one that was on was sucking hot air from the exhaust manifold...nice design you got there. I'm going to try it

@thelonewrangler1008 Год назад

Im currently embarking on doing this mod to a tj and i enjoyed watching your version of it. Thanks for the vid

@SomeGuyOutside Год назад

Very welcome! I’ll be getting around to a gen 2 version one day, hope yours goes well!

@chrissweisberger7509 Год назад

been looking at the online brands and you giv me the idea that i can do this - thanks

@SomeGuyOutside 11 месяцев назад

Hope you went for it and did it!

@chriswheeler5150 Год назад

Youre smart as hell man

@SomeGuyOutside 11 месяцев назад

I stand on the shoulder of jeepin giants!

@colt45northtexas 2 года назад

I said the same thing about the lightning just before you did. Haha "what the"

@GF_Burke 2 года назад

Nice man. I just bought a Spectre (K&N knock off) for the stock air box. 3in hole saw on the stock box - computer side. Now she breaths for $20. But... I'll probably end up doing this later to make the under hood space.

@SomeGuyOutside 2 года назад

My only “note” is the intake noise is louder than I expected it to be, not terrible but it is quite a bit louder. It certainly made a lot of space I think I’m gonna be putting a second battery up there!

@GF_Burke 2 года назад

@@SomeGuyOutside Ya battery. My 79f150 300 4x4 has a toolbox in that spot.

@minegun3 2 года назад

I built mine as a clone more or less of the thor intake. i made mine out of 3in stainless steel exhaust tubing. pie cut the angles for the bends and welded it all together. and made a flat cover plate to cover the hole. But i did use a foam UNI pod filter. it tones down the intake noise a bit vs a paper filter. total cost was about 50 bucks for me to make and a few hours of time.

@SomeGuyOutside 2 года назад

I’m haven’t had an issue with the CPVC but making a stainless steel would absolutely be a great look. I’m a slow/novice fabricator so I take my time a bit more than you’d have to. Thanks for the heads up on the foam cover!

@josephhall6244 10 месяцев назад

nice cheapest set up.. dont mind me asking what size of that white elbow and black pipe is..

@stephanoeaton9769 6 месяцев назад

I love the hood vents...did u do a video for that?

@SomeGuyOutside 5 месяцев назад

I did do a video on the hood vents! Just made em out of floor vents from Home Depot!

@crashtke 2 года назад

Another option would be silicone and metal pipes. Lots of kits available out there if the pcv ever gives you issues.

@SomeGuyOutside 2 года назад

I love the look of the THOR kit and if I had the money and no time I would have gone with them but I like to challenge my rather limited "fabrications" ability whenever possible. Plus if the PVC ever gives me trouble Ill get to make a clickbait video with some title like "DONT DO THIS MOD TO YOUR JEEP" 😂😂

@toddhoffmaster6057 Год назад

@@SomeGuyOutside You could also use header wrap around the pvc intake to prevent the heat from being an issue.

@officialWWM 2 года назад

I built mine out of pvc. It’s been on there for a year or so now and it still works fine…

@SomeGuyOutside 2 года назад

I was pretty optimistic, just in researching this project I saw A LOT of hate/sh*t posting on Reddit and Naxja of people saying you can’t and terrible things will happen. A little over three months on mine and it’s doing great!

@officialWWM 2 года назад

@@SomeGuyOutside most of the people making those comments have never even tried it!

@bombdiggitydave3881 Год назад

Excellent DIY COLD AIR INTAKE fab video. 👍 I will use your idea as inspiration for a ZJ. My only concern is rain/water coming off the windshield and draining into the intake. If you daily your XJ how do you deal with liquid intrusion?

@SomeGuyOutside Год назад

The cowl on the XJ (or atleast mine) isn’t permeated above the passenger side as it is on the drivers side. So Water won’t fall directly onto the filter and should be draining before it can build up to a high enough level inside the cowl before coming close to the filter. Or that was the plan and so far here in Washington it’s not had any issues as my daily driver. Hope this can help in some way! It was/is a worry of mine but it has yet to be an issue

@bombdiggitydave3881 Год назад

@@SomeGuyOutside Actually your response and detailed explanation is helpful and appreciated. Thanks for the reply and your helpful video.

@DustySteel 2 года назад

Rad 2-Door XJ. I have a 97 2-Door XJ that I’m in the middle of putting a long arm lift with 35s.

@SomeGuyOutside 2 года назад

Very cool! I got mine about five years ago totally stock, just been doing little projects here and there building it over time. Long arms have been on my list since about when i first got this jeep. Did you reinforce the frame before going long arm? I know some people do, some Dont.

@DustySteel 2 года назад

@@SomeGuyOutside I want to but don’t have the funds yet. Needing a new trac bar, suspension, and tires I figured I’d just put a lift on. Now I realize that I also would need to do all kinds of stiffeners. If I had a garage I would invest in a welder. I won’t really be going offroad until I can get stiffeners and regear the axles for the 35s.

@DustySteel 2 года назад

@@SomeGuyOutside I literally just got done taking the rear shocks off and got super lucky and the upper shock bolts didn’t break.😁👍

@cullenlumma905 4 месяца назад

Do you have a sharable blueprint for the box you had to make?

@DustySteel 2 года назад

Awesome video! Are you going to paint the bit that you made out of aluminum?

@SomeGuyOutside 2 года назад

Thank you! So far I’ve left it bare aluminum! I kinda dig the shinny look of it. I hope to be moving up to a higher quality welder and begin welding aluminum so I might replace/update it in the future.

@DustySteel 2 года назад

@@SomeGuyOutside looks sick either way!!

@texture6 2 года назад

I like you hood setup, please tell me you have a DIY video

@SomeGuyOutside 2 года назад

I do indeed!! Check out my diy hood vent video from a few months back!

@Mauser1965 Год назад

Curious if installing some Kilmat type of noise suppression would reduce the noises in the firewall.

@SomeGuyOutside 11 месяцев назад

Honestly i think ive gotten used to it (lost more of my hearing). But I do think I'll be redoing it one of these days. Still looking the right design replacement and it will for sure have some level of noise dampening going in.

@MRLiquidTUBE 2 года назад

I'm searching K&N's website for the AT-6091 and it doesn't seem to exist anymore. =[ any ideas on alternatives?

@SomeGuyOutside 2 года назад

I believe TrailHeadOffroad sells just the filter (they also sell the full build kit) for more than the K&N was. Sorry to hear that, whole worlds a little out of wack so it might be brought back in eventually!

@Jeepster84 2 месяца назад

Is this 3” pvc pipe?

@christophervillareal6151 2 года назад

Does the longer line of travel for the intake affect your performance at all

@SomeGuyOutside 2 года назад

I don’t believe that has any measurable effect on performance. Certainly not one that I have noticed

@richtyler1353 2 года назад

Can you follow up with your mileage did you see a little improvement

@SomeGuyOutside 2 года назад

I’ll track the next tank I fill. I can’t imagine there will be a noteworthy change but I’ll do it to atleast find out it didn’t make it worse (hopefully 😂)

@joekleko7972 2 года назад

Does this affect air flow into the cabin when you use the heater controls?

@SomeGuyOutside 2 года назад

Not that I have noticed, my AC and heater work great. (They’ll break now that I say that I’m sure). I’m confident the air pickup that is inside the cowl is the cause for the severe increase in audible noise of the cowl. I’ve been playing around with the possibility of sealing off the two sections. (My concern is more to lessen the noise a intake noise a tad more than damage to the vents but that’s totally a possibility, that suction could be working the fans harder I suppose) If I ever manage to do so I will make a video about how!

@kermitshatley1903 2 года назад

Seems like the heat off of the engine would kill the cool air idea, the way it looks,the pipe laying on, crossing over the manifold,valve cover will keep it hot and the air coming in is heated by that.I think the way coming from factory is better and cooler air. But to each their own,your fabrication skills are great and you have more patience than me,great job on what you did.

@SomeGuyOutside 2 года назад

Thank you very much! I deliberated over trying to cross over the block to have access to the relatively unused firewall area on the passengers side (like I did) or try to keep it on the drivers side but I couldn’t come up with a decent enough spot on the drivers side in the firewall. I THINK the air moving into the intake will be moving faster than it could be heated up in the time it’s in the pipe over the crank but that’s for a scienterst to answer than myself.

@DustySteel 2 года назад

No matter where the piping is routed either way the intake manifold sits directly above the header. Having a cowl intake like this would be way better over stock because the stock air box doesn’t really pull in fresh air.

@kermitshatley1903 2 года назад

@@DustySteel Like I said to each their own

@Mauser1965 Год назад

There's always a heat exchange either way.

@TOPCAT_949 5 месяцев назад

Has your setup ever been smogged to see if it could pass emissions?

@SomeGuyOutside 4 месяца назад

My jeep was last smogged in 2017 when Washington state last had smog checks (it passed at that time) we are no longer required to do smog checks. I do not know if it would pass, I have my doubt but that is not based on any science just the fact I built this stuff. GO COUGS!

@kevinc9934 2 года назад

what about when it rains?

@SomeGuyOutside 2 года назад

The filter is above the “water level” in the cowl area and there isn’t any water getting in directly above it to drip down onto It. I don’t believe there will be and there has not been any issue so far and it’s been in the rainy season of the pnw not much more of a rainy area you could get.

@TOBAYSON 2 года назад

I think , that the hood vent in front of the cowl , is not helping 🤔

@SomeGuyOutside 2 года назад

It had crossed my mind throughout making it, decided pros of both outweigh the con of them both together or having just one or the other. Overall still cooler air than the air in the engine bay would be by a substantial margin with the vents and intake and raised the intake over a foot higher from the OEM waterline level

@TOPCAT_949 5 месяцев назад

Go Cougs

@evan_alexanderr 2 года назад

Give it to us straight, how’s it holding up?

@SomeGuyOutside 2 года назад

It’s holding up great, only thing I’ve done since is reoiled the filter and soldered the aluminum box. I expected the rubber 90 to start breaking down from moving with the motion of the engine but no such noticeable wear has occurred. What I will say again is it’s a lot louder than I expected it to be, I’d heard videos online and heard people say the same thing. It’s the only part I’m working on changing at the moment!

@luiscota7316 Год назад

Cuando llueve se junta mucho el agua hai

@SomeGuyOutside Год назад

Rain won’t fall right onto the filter as the slots in the cowl are on the driver side and will drain at a lower level than the filter so it’s no more likely than the stock box to get water in it. I live in the PNW and get very heavy rains no problem so far, you’ll see an update if it ever does 👍🏻

@equals-kl9hm Год назад

If your intention is to "intake" cooler air why not install a snorkel kit?

@SomeGuyOutside 11 месяцев назад

If I could, I would. On more than a few years such as mine, you can see in the video that the brake booster and CPU block most of the drivers side firewall and the battery, fuse box and and fluid reservoirs blocks the passenger side fire wall. I am currently considering relocating the fluids and seeing if I can route one out that side.

@equals-kl9hm 11 месяцев назад

@@SomeGuyOutside that makes sense. Thank you for the information. Good luck with your future plans.