More progress on the cabin air filter design. Since last week, the filter cartridge box has been redesigned from top load to front load design. This allows for a little more under-cowl clearance and also much easier filter cartridge changes. Some other design improvements have been made as well. All parts have been successfully printed in ABS plastic and dry fitted as of this morning.
Here's a quick video of the 3D assembly being orbited in CAD.
The design is comprised of five printed parts, four of which get glued together permanently. Hardware used is one #8 speed nut and one #8x3/4" phillips flanged rounded head screw, aside from the three screws for attaching the factory duct to the sub-cowl. The current cartridge box is designed specifically for the K&N VF1010 reusable cabin filter (for late model Jx Jeeps), but could be easily modified to use any facsimile of the Mopar 55111302AA filter. I've got a couple sizes and types of foam tape to try out for the gasket and may also take a shot at printing one in TPU if I feel froggy.
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I'm considering this current design to be a functional prototype and will be bonding all of the parts (possibly later this evening), installing on my LJ and giving it a real-world test.