JJC

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I'll leave this up as reference for those looking to make a simple DIY air intake and adapt a cone filter. I've since made a new intake which can be seen here: JJC 2.0L Cold Air Intake - Take 2 | MaverickTruckClub - 2022+ Ford Maverick Pickup Forum, News, Owners, Discussions

IMG_6549.jpg


Parts used:
Spectre Performance SPE-9429 3" 22º Aluminum Elbow
Airaid 700-492 Universal Clamp-On Air Filter
1/2 in. Grommet

Alternate filter options:
AEM DryFlow Air Filter: Flange Diameter: 3 In, Filter Height: 6.5 In, Flange Length: 0.625 In, Shape: Round Tapered, 21-2036DK
aFe 21-30028 MagnumFlow Universal Clamp-on Air Filter with Pro Dry S
K&N Universal Clamp-On Air Filter: High Performance, Premium, Washable, Replacement Filter: Flange Diameter: 3 In, Filter Height: 5.5 In, Flange Length: 1.125 In, Shape: Round Tapered, RG-1001RD
K&N Universal Clamp-On Air Filter: High Performance, Premium, Washable, Replacement Filter: Flange Diameter: 3 In, Filter Height: 5.75 In, Flange Length: 0.75 In, Shape: Round Tapered, RU-5111
K&N Universal Clamp-On Air Filter: High Performance, Premium, Washable, Replacement Filter: Flange Diameter: 3 In, Filter Height: 6 In, Flange Length: 1.75 In, Shape: Round Tapered, RE-0930

Tools required:
7mm socket for OEM hose clamp
Pry tools or flathead screw driver
Whichever size socket you need for your filter, in my case this was an 8mm
SHARPTOOL 3/16 to 7/8 Inches HSS Step Drill Bit for Metal, Plastic, Wood, Aluminum, Heavy Duty Unibit with Multi Hole Sizes
*As an Amazon Associate I earn from qualifying purchases.

I happened to find this particular filter on eBay for ~$25 so that's why I went with it, most universal filters with a 3" inner flange diameter will work, but here are the dimensions of the filter that I used for your reference. Fitment is pretty tight with the 8" tall filter, a 6-7" would likely be ideal.

Shape: Round Tapered
Flange ID: 3 in (76mm)
Filter Height: 8 in (203mm)
Filter Base Ø: 6 in (152mm)
Filter Top Ø: 4.625 in (117mm)

First, you will need to drill a hole in the Spectre elbow for the sensor. I used a step bit and drilled to 5/8", the bit listed above worked really well.

Next, insert the grommet into the newly drilled hole.

You can now remove the factory intake lid and filter. I disconnected and removed the sensor first. For the lid of the filter housing, there are two clips towards the driver's side fender, the factory hose clamp can be loosened with a 7mm socket. Part of the tube that directs fresh air into the intake box will also need to be removed, this has two small clips. I just used a small pry tool to remove this piece.

After removing the upper portion of the OEM intake, you can insert the elbow, insert and re-connect the sensor, attach the filter and tighten in place. I left the lower part of the OEM intake enclosure in place to support the filter for now.

For Part 2 I will be making a heat shield/enclosure, and eventually a Part 3 in which I hope to rework the upper grille to direct even more fresh air to the custom enclosure. I realized at the end that I did not take any in-progress pictures, sorry about that! It's pretty simple to get to this point, the next steps will be more involved so I plan to document those in greater detail. The truck was happy with the new intake, no check engine lights or odd driving characteristics. The added sound is great but not obnoxious by any means. There seems to be a noticeable improvement in throttle response but I have no definitive proof of any added gains. Total cost all-in thus far is just under $50.

IMG_6550.jpg
IMG_6551.jpg
IMG_6552.jpg
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Evil2ltr

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jmcgon237

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Excellent innovation. When you take out the lower part of the original air filter you will be able to see where is got it's air from and it could provide you your source of fresh air. Please update when you can.
 
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JJC

JJC

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Excellent innovation. When you take out the lower part of the original air filter you will be able to see where is got it's air from and it could provide you your source of fresh air. Please update when you can.
Thanks. Here's where the original intake pulls air from. Inlet looks to be behind the upper grille area and then it is routed to the filter housing:
IMG_6557 (1).jpg


Here's the part of that which I had to remove for my filter to fit, this is just a downward tube to direct air beneath the OEM filter:
IMG_6558 (1).jpg


As you can see below, the entire upper portion of the grille is molded solid, so no air coming in here. I'm hoping to open up the inlets in the between the grille bars so air can flow directly into the enclosure that I make. I'm not 100% sure if it will work as I'm planning though. I'll have a better idea of what exactly is going on under/behind all of this plastic once I remove it.
IMG_6559 (1).jpg
 

jmcgon237

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Thanks. Here's where the original intake pulls air from. Inlet looks to be behind the upper grille area and then it is routed to the filter housing:
IMG_6557 (1).jpg


Here's the part of that which I had to remove for my filter to fit, this is just a downward tube to direct air beneath the OEM filter:
IMG_6558 (1).jpg


As you can see below, the entire upper portion of the grille is molded solid, so no air coming in here. I'm hoping to open up the inlets in the between the grille bars so air can flow directly into the enclosure that I make. I'm not 100% sure if it will work as I'm planning though. I'll have a better idea of what exactly is going on under/behind all of this plastic once I remove it.
IMG_6559 (1).jpg
A lesson I learned from a similar attempt years ago. Make sure rain and snow doesn't have direct access to the filter. Wet snow was my downfall. I was thinking thru the hurdles that need resolved. Ford got cooler fresh air from outside the engine bay (without the snow) but needed piping to get that accomplished. I would also assume that when driving, Ford's air cleaner intake pipe even has air forced in from the air coming thru the lower grill. Have fun working out all the issues.
 

Decayed

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Nice work. How does it run? Any noticeable difference in power?

Here's a link to a video on grille removal.

 

WasChops

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I recently put together the first part of my custom intake, thought I'd share my progress as I go.

Parts used:
Spectre Performance SPE-9429 3" 22º Aluminum Elbow
Airaid 700-492 Universal Clamp-On Air Filter
Everbilt 1/2 in. Black Neoprene Grommet-812028

Tools required:
7mm socket for OEM hose clamp
Pry tools or flathead screw driver
Whichever size socket you need for your filter, in my case this was an 8mm
5/8" hole saw bit

I happened to find this particular filter on eBay for ~$25 so that's why I went with it, most universal filters with a 3" inner flange diameter will work, but here are the dimensions of the filter that I used for your reference. Fitment is pretty tight with the 8" tall filter, a 6-7" would likely be ideal.

Shape: Round Tapered
Flange ID: 3 in (76mm)
Filter Height: 8 in (203mm)
Filter Base Ø: 6 in (152mm)
Filter Top Ø: 4.625 in (117mm)

First, you will need to drill a hole in the Spectre elbow for the sensor. I used a 5/8" hole saw bit.

Next, insert the grommet into the newly drilled hole.

You can now remove the factory intake lid and filter. I disconnected and removed the sensor first. For the lid of the filter housing, there are two clips towards the driver's side fender, the factory hose clamp can be loosened with a 7mm socket. Part of the tube that directs fresh air into the intake box will also need to be removed, this has two small clips. I just used a small pry tool to remove this piece.

After removing the upper portion of the OEM intake, you can insert the elbow, insert and re-connect the sensor, attach the filter and tighten in place. I left the lower part of the OEM intake enclosure in place to support the filter for now.

For Part 2 I will be making a heat shield/enclosure, and eventually a Part 3 in which I hope to rework the upper grille to direct even more fresh air to the custom enclosure. I realized at the end that I did not take any in-progress pictures, sorry about that! It's pretty simple to get to this point, the next steps will be more involved so I plan to document those in greater detail. The truck was happy with the new intake, no check engine lights or odd driving characteristics. The added sound is great but not obnoxious by any means. There seems to be a noticeable improvement in throttle response but I have no definitive proof of any added gains. Total cost all-in thus far is just under $50.

IMG_6549.jpg
IMG_6550.jpg
IMG_6551.jpg
IMG_6552.jpg
Curious what is the performance increase with this mod?
 

john218

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I recently put together the first part of my custom intake, thought I'd share my progress as I go.

Parts used:
Spectre Performance SPE-9429 3" 22º Aluminum Elbow
Airaid 700-492 Universal Clamp-On Air Filter
Everbilt 1/2 in. Black Neoprene Grommet-812028

Tools required:
7mm socket for OEM hose clamp
Pry tools or flathead screw driver
Whichever size socket you need for your filter, in my case this was an 8mm
5/8" hole saw bit

I happened to find this particular filter on eBay for ~$25 so that's why I went with it, most universal filters with a 3" inner flange diameter will work, but here are the dimensions of the filter that I used for your reference. Fitment is pretty tight with the 8" tall filter, a 6-7" would likely be ideal.

Shape: Round Tapered
Flange ID: 3 in (76mm)
Filter Height: 8 in (203mm)
Filter Base Ø: 6 in (152mm)
Filter Top Ø: 4.625 in (117mm)

First, you will need to drill a hole in the Spectre elbow for the sensor. I used a 5/8" hole saw bit.

Next, insert the grommet into the newly drilled hole.

You can now remove the factory intake lid and filter. I disconnected and removed the sensor first. For the lid of the filter housing, there are two clips towards the driver's side fender, the factory hose clamp can be loosened with a 7mm socket. Part of the tube that directs fresh air into the intake box will also need to be removed, this has two small clips. I just used a small pry tool to remove this piece.

After removing the upper portion of the OEM intake, you can insert the elbow, insert and re-connect the sensor, attach the filter and tighten in place. I left the lower part of the OEM intake enclosure in place to support the filter for now.

For Part 2 I will be making a heat shield/enclosure, and eventually a Part 3 in which I hope to rework the upper grille to direct even more fresh air to the custom enclosure. I realized at the end that I did not take any in-progress pictures, sorry about that! It's pretty simple to get to this point, the next steps will be more involved so I plan to document those in greater detail. The truck was happy with the new intake, no check engine lights or odd driving characteristics. The added sound is great but not obnoxious by any means. There seems to be a noticeable improvement in throttle response but I have no definitive proof of any added gains. Total cost all-in thus far is just under $50.

IMG_6549.jpg
IMG_6550.jpg
IMG_6551.jpg
IMG_6552.jpg
Looking forward to parts 2 and 3!!:rolleyes:
 

Sjbuck2021

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Curious what is the performance increase with this mod?
More intake noise along with the road noise isn't what I want. I'm sure the few hp gain isn't going to make much difference. To each his own.
 

jpage8645

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I recently put together the first part of my custom intake, thought I'd share my progress as I go.

Parts used:
Spectre Performance SPE-9429 3" 22º Aluminum Elbow
Airaid 700-492 Universal Clamp-On Air Filter
Everbilt 1/2 in. Black Neoprene Grommet-812028

Tools required:
7mm socket for OEM hose clamp
Pry tools or flathead screw driver
Whichever size socket you need for your filter, in my case this was an 8mm
5/8" hole saw bit

I happened to find this particular filter on eBay for ~$25 so that's why I went with it, most universal filters with a 3" inner flange diameter will work, but here are the dimensions of the filter that I used for your reference. Fitment is pretty tight with the 8" tall filter, a 6-7" would likely be ideal.

Shape: Round Tapered
Flange ID: 3 in (76mm)
Filter Height: 8 in (203mm)
Filter Base Ø: 6 in (152mm)
Filter Top Ø: 4.625 in (117mm)

First, you will need to drill a hole in the Spectre elbow for the sensor. I used a 5/8" hole saw bit.

Next, insert the grommet into the newly drilled hole.

You can now remove the factory intake lid and filter. I disconnected and removed the sensor first. For the lid of the filter housing, there are two clips towards the driver's side fender, the factory hose clamp can be loosened with a 7mm socket. Part of the tube that directs fresh air into the intake box will also need to be removed, this has two small clips. I just used a small pry tool to remove this piece.

After removing the upper portion of the OEM intake, you can insert the elbow, insert and re-connect the sensor, attach the filter and tighten in place. I left the lower part of the OEM intake enclosure in place to support the filter for now.

For Part 2 I will be making a heat shield/enclosure, and eventually a Part 3 in which I hope to rework the upper grille to direct even more fresh air to the custom enclosure. I realized at the end that I did not take any in-progress pictures, sorry about that! It's pretty simple to get to this point, the next steps will be more involved so I plan to document those in greater detail. The truck was happy with the new intake, no check engine lights or odd driving characteristics. The added sound is great but not obnoxious by any means. There seems to be a noticeable improvement in throttle response but I have no definitive proof of any added gains. Total cost all-in thus far is just under $50.

IMG_6549.jpg
IMG_6550.jpg
IMG_6551.jpg
IMG_6552.jpg
You can also use this air filter for 1/2 the cost. Spectre Performance SPE-9732 Universal Clamp-On Air Filter: Round Tapered; 3 in/3.5 in/4 in (102 mm/89 mm/76 mm) Flange ID; 8.75 in (222 mm) Height; 6 in (152 mm) Base; 4.75 in (121 mm) Top
 

Sjbuck2021

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Nice work. How does it run? Any noticeable difference in power?

Here's a link to a video on grille removal.

We it screw up emissions test?
 

Decayed

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We it screw up emissions test?
Supposedly not. It's a simple, non destructive install. If you fail, just put the old parts back. However, there has been some debate as to whether you will invalidate your factory warranty. I wouldn't go to the dealer for service sporting that.
 
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