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Want the benefits of a Cold-Air Intake (CAI) such as K&N`s, AEM`s, Air Raid`s, et cetera, but don`t have the cash to blow? Not too sure about a "kit" off eBay? Want the satisfaction of using your hands (and tools) to create one of your own? These instructions will work for 1996 through end of production for Chevrolet Blazers, GMC Jimmys, and Oldsmobile Bravadas equipped with the 4.3 Vortec.
The following will show you how to make your own CAI, all for under $100; all with pretty common tools (and with a little help from a friend). There is no drilling required and you can return your vehicle to stock if you so wish with no signs of any modifications made! I will attempt to be as informative as possible, please feel free to reply or PM with any questions. I am by no means a professional mechanic, but that`s the beauty of this modification-you don`t need to be! Please read entire how-to if you intend on building one of your own as there are some different options you may choose that will affect appearance and/or price.
TOOLS NECESSARY:
Phillips head screwdriver
Flathead screwdriver
10mm wrench or 10mm deep-well socket and ratchet
Hammer
Sheet metal snips (I used 7" straight snips, you may have better luck with smaller but I did not want to cut FEET of sheet metal with anything smaller)
Needle nose pliers
Scissors
Utility knife
Work gloves (if you intend on cutting the sheet metal yourself)
Sharpie marker
TOOLS NICE TO HAVE IF YOU HAVE ACCESS:
Center punch
Drill with 1/4" metal bit
Sheet metal shear
Sheet metal bender
Band saw/pipe cutter/Sawzall
3.5" metal hole saw
SUPPLIES NEEDED:
The following supplies were purchased at my local hardware store:
Minimum 24" wide by 24" long sheet metal (I used 24" wide by 30" long just to be safe)
3/4" by 1/2" corner braces (or similar hardware)
3" High-heat capable rubber coupling(usually comes with hose clamps but just in case...)
Two 3" hose clamps
Two (or more if you prefer) each of machine screws, washers, and nuts (all in same or smaller diameter as holes punched)
One sheet metal screw (see Step 2 under "Installation of Heat Shield..." for size)
4-5 feet of 3/8" fuel line (or similar high-heat capable material, i.e. hood weather-stripping)
7-8 inches of 1/4" fuel line or washer fluid hose
1 can of high heat paint (your choice of color, there are links under "Conclusion" that show the difference between flat black and aluminum)
1 tube of RTV sealant (not necessary)
3" Mandrel-bent, 45 degree pipe (I got mine from a local performance garage)
Spare cardboard lying around (a case of beer box is large and rigid enough)
This how-to got cut off as a result of a forum hack.
Here is a link to a slideshow with descriptions and pictures:
How-To: Handmade heat shield and intake
