Finally received the air box and started the modification. I opted to plastic weld mine up ... my old cheapo 20 watt soldering iron was perfect ... not too hot to deteriorate the plastic but hot enough to melt it.
As many have done, I opted to shorten the box as the MAF portion in the factory Ford box is not needed on the Jeep.
I cut both sides and "tacked" it in once I was happy with the height. I did grind the tabs that were previously used to click the old MAF unit in place.
As you can see above, I had a small broken piece on the outer lip but that was easily fixed with a bit of plastic ... and some smoothing ...
Here is the lower part after "welding"
... testing for leaks ...
I opted to leave the drain hole in the filterbox ... I may or may not fill it at a later date since the airbox is high enough for any fording we might come across. Anyone know if it creates a whistle sound? I would guess not since it came from the Ford factory like that.
Here it is ready for action (it looks crooked in the pic but the base is perfectly square)
I will see if there is a way to use the rubber tabs/feet .. perhaps relocating them somewhere ...
Next step will be to place the entire unit in the engine bay and decide if I go with a 90deg 4" with the windstar's bellow (and plug the hole) or, like most have done, get a 4" to 3" silicone elbow ... the deciding factor will be ease of maintenance during the raid.
