Building Homer (2005 TJ Build Thread)

[FarFire70]

Is the Windstar 3 1/8" tubing? If so then we'd need to reduce from 4" to that? They make some reducers to 3.5" so then a short piece of hose that went from 3.5" to 3.125"

That is for the rubber snorkel the WinStar air filter intake fit into. I can post some pictures of that piece tomorrow.

That's one of the issues on using this air filter container is that it is a press fitting at the firewall. I didn't realize that it wasn't as supportive from others who have used it. Learning...

 

[FarFire70]

They make this support bracket which is what I'm using.

View attachment 552412
https://www.spectreperformance.com/9710-t-bolt-clamp-bracket

They also make this one but don't say what diameter the tube is.

View attachment 552413
https://www.spectreperformance.com/9702-air-intake-support-bracket

If I stay with the Windstar I will definitely need to design something like this.. it needs support to keep it from rubbing on all of the cables that go to the throttle body.

 

[Wildman]

That is for the rubber snorkel the WinStar air filter intake fit into. I can post some pictures of that piece tomorrow.

That's one of the issues on using this air filter container is that it is a press fitting at the firewall. I didn't realize that it wasn't as supportive from others who have used it. Learning...

I wonder if you could somehow use this at the firewall?

https://www.spectreperformance.com/accessories/9602-air-filter-inlet-adapter-velocity-stack

 

[Wildman]

They do make a 3" duct mounting plate.

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

 

[Wildman]

Here's their 4" air filter housing

https://www.spectreperformance.com/accessories/9833-air-filter-housing

 

[Rickyd]

Intake had a lot of issues. Hitting the hood is biggest issue. Getting out off sitting on all the cables is next. Crappy connection of the breathe hose.

Hood issue needs to be tracked first.

Here's where I drilled the firewall.

View attachment 552396

Clears the grounding nut and the spot welds.

Loosened all the clamps and ran a tape test.

View attachment 552397

View attachment 552398

View attachment 552399

You can see where the hood rests on the filter box.

View attachment 552400

I need to lift the rear of the filter box to clear the cables by at least a bit. But that causes the filter box to go even higher at the firewall making the problem worse.

I'm struggling to think I have a better solution than cutting into the filter box and adding a flat panel... I placed my hole in the firewall just like others I'd seen use this so I'm struggling. Surprised that they didn't deal with this issue of Hood impact..

This is using the Windstar filter box that so many others have used and I'm struggling that I'm having a problem here that I didn't see others having...

Maybe a heat gun will soften the housing enough to be able to push a section in?

 

[Wildman]

For your breather hose I used a barbed bulkhead fitting and cut the barbs off the threaded side.

https://www.amazon.com/Biaungdo-Sta...lk-Straight/dp/B0B82LR65S/?tag=wranglerorg-20

I used Red Loctire on the threads & staked them too to keep the nut on inside the tube.

 

[FarFire70]

For your breather hose I used a barbed bulkhead fitting and cut the barbs off the threaded side.

View attachment 552428

https://www.amazon.com/Biaungdo-Sta...lk-Straight/dp/B0B82LR65S/?tag=wranglerorg-20

I used Red Loctire on the threads & staked them too to keep the nut on inside the tube.

100% needs to be a solution like this! I joked on your thread about ensuring the nut didn't get loose but you are right (any me - with little effort - pulling mine out) shows that's the long term solution.

 

[FarFire70]

Posted the question over here:

Post in thread 'Windstar Intake Clearance - Hitting Hood'

Aug 21, 2024

View attachment 552622

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:

View attachment 552621

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.

• FarFire70

• 

And got lots of great feedback. I'm still up in the air.

My initial options from the feedback

• Create a way to build a 2-3" spacer pipe
• Rivet a replacement place and drill a new hole lower

Lots of pros/cons on both.

I'm thinking now.

 

[FarFire70]

My focus for the upcoming weekend is get all the painted steel polishing and waxed. I don't like that I have some of the painted steel polished, but not waxed.

So I'll think and work the other upgrades.

But I want to get the paint cleaned up and protected again.

 

[NashvilleTJ]

Posted the question over here:

Post in thread 'Windstar Intake Clearance - Hitting Hood'

Aug 21, 2024

View attachment 552622

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:

View attachment 552621

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.

• FarFire70

• 

And got lots of great feedback. I'm still up in the air.

My initial options from the feedback

• Create a way to build a 2-3" spacer pipe
• Rivet a replacement place and drill a new hole lower

Lots of pros/cons on both.

I'm thinking now.

Or don’t worry about it if it’s not pressing hard enough to cause an issue. My filter assembly cotacts that rear hood brace just a bit - enough to rub off a little paint. Has not caused any trouble, and mine is metal. Your plastic assembly would be fine I’d bet.

 

[FarFire70]

Or don’t worry about it if it’s not pressing hard enough to cause an issue. My filter assembly cotacts that rear hood brace just a bit - enough to rub off a little paint. Has not caused any trouble, and mine is metal. Your plastic assembly would be fine I’d bet.

Thanks! It's minimal but I do worry it'll wear the paint over time. I guess that can be a 'monitor' situation.

Where I have bigger concerns is that the rubbing will exacerbate as I build support(s) to get the tube off the cabling. That's going to push the filter housing up a touch.

 

[Wildman]

Thanks! It's minimal but I do worry it'll wear the paint over time. I guess that can be a 'monitor' situation.

Where I have bigger concerns is that the rubbing will exacerbate as I build support(s) to get the tube off the cabling. That's going to push the filter housing up a touch.

Does moving it away from the firewall a little help to put it into a better position?

And for the paint rubbing off, can you get some foam or something where it's going to get the hood to help protect it some?

 

[FarFire70]

Does moving it away from the firewall a little help to put it into a better position?

Not sure yet. Hoping to have time this weekend to mockup different approaches.

And for the paint rubbing off, can you get some foam or something where it's going to get the hood to help protect it some?

I have thought about protecting the paint, if I don't move the box down and it stays in contact with the hood.

I plan to replace my OEM faded/cracked clear paint protection film on the doorsills. I thought I could re-use some of the new material (TBD what material I'm going with) on the hood support to minimize/eliminate paint wear.

I need to do this elsewhere on from the hood — like where the hood bumpers (underside of the grill) contact the grill because they've worn through the paint...

 

[Wildman]

Not sure yet. Hoping to have time this weekend to mockup different approaches.



I have thought about protecting the paint, if I don't move the box down and it stays in contact with the hood.

I plan to replace my OEM faded/cracked clear paint protection film on the doorsills. I thought I could re-use some of the new material (TBD what material I'm going with) on the hood support to minimize/eliminate paint wear.

I need to do this elsewhere on from the hood — like where the hood bumpers (underside of the grill) contact the grill because they've worn through the paint...

I'll try to find it but there are some companies that make some really tough clear paint protecter stuff. I used it on my Harley so I wouldn't scratch the fuel tank as I slide my right leg (has prosthetic) over it when getting on and off.

 

[FarFire70]

I'll try to find it but there are some companies that make some really tough clear paint protecter stuff. I used it on my Harley so I wouldn't scratch the fuel tank as I slide my right leg (has prosthetic) over it when getting on and off.

Appreciate any recommendations!

 

[Wildman]

https://www.rg-racing.com/browsetype/SecondSkin/Universal/Universal/SCPGUARDUNI002/

https://www.rg-racing.com/Partners/all/United-States/all/

 

[FarFire70]

https://www.rg-racing.com/browsetype/SecondSkin/Universal/Universal/SCPGUARDUNI002/

https://www.rg-racing.com/Partners/all/United-States/all/

Damn - not for cheap

I've saved it in my 'Parts Research' bookmarks. Gotta do metric to inches conversions to see if the sizes would even meet my needs — freaking metric

 

[Wildman]

Here is where I sourced a lot of my silicone hoses I used.

https://www.pegasusautoracing.com/advcat.asp?CategoryID=SILICONEHOSE

 

[FarFire70]

Received my paint shipment! This is just for touch-ups so not to spray, yet. That will require larger quantity.

I ordered primer and color and clear coat.

Great packaging.

Color looks really good on first exam.

It looks closer in color in person than this pic shows.

Haven't applied the color yet so we all know the final dried product is what matters but this looks promising.