Novak Conversions Jeep Wrangler TJ radiator

Windstar Intake Clearance - Hitting Hood

FarFire70

FarFire70

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I've installed the Windstar Air intake filter box that many have put in but am having an issue with hood clearance.

I didn't see this address in other posts so I wanted to put this out to see if anybody had a good solution.

I drilled firewall hole here:

1000007137.jpg


But I'm finding that the hood impacts the filter box as you can see through this tape test and the spots on the air filter box.

1000007140.jpg


1000007141.jpg


1000007142.jpg


I haven't seen this issue on other installs so I'm curious if anybody has been seen or dealt with this problem.

I can't see that I've got much room to grind down given the grounding bolt and spot welds.
 
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I've never seen an intake like that. I'm confused, is it pulling air from in the cabin? Thats right by the heater core right, whats the advantage?
 
inkedrose said:
I've never seen an intake like that. I'm confused, is it pulling air from in the cabin? Thats right by the heater core right, whats the advantage?
Click to expand...

It's pulling exterior air from the cowl area where the wiper motor lives. The interior HVAC does pulls from this area when not recirculating.

Advantage is that it's exterior air not heated but the engine bay. Depending on your off road environment, it puts the air intake for the engine at the windshield, not the headlight. So less likely to take in water on deep water crossing.
 
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FarFire70 said:
It's pulling exterior air from the cowl area where the wiper motor lives. The interior HVAC does pulls from this area when not recirculating.

Advantage is that it's exterior air not heated but the engine bay. Depending on your off road environment, it puts the air intake for the engine at the windshield, not the headlight. So less likely to take in water on deep water crossing.
Click to expand...

Cool! Thats the first one I've seen so far
 
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FarFire70 said:
I've installed the Windstar Air intake filter box that many have put in but am having an issue with hood clearance.

I didn't see this address in other posts so I wanted to put this out to see if anybody had a good solution.

I drilled firewall hole here:

View attachment 552405

But I'm finding that the hood impacts the filter box as you can see through this tape test and the spots on the air filter box.

View attachment 552406

View attachment 552407

View attachment 552408

I haven't seen this issue on other installs so I'm curious if anybody has been seen or dealt with this problem.

I can't see that I've got much room to grind down given the grounding bolt and spot welds.
Click to expand...

Seeing Wildmans post can you space the housing back with short piece of silicone tubing to bridge/ space off the firewall 4”?
 
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@SkylinesSuck What are you using on the firewall to connect to? From his pictures he had the Windstar housing sticking through the hole. So he need something to connect to there .
 
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Wildman said:
@SkylinesSuck What are you using on the firewall to connect to? From his pictures he had the Windstar housing sticking through the hole. So he need something to connect to there .
Click to expand...

Nothing is actually *attached* to the firewall. It just goes through it. There is a velocity stack on the other side which is bigger than the hole so it stays put.

PXL_20230105_185516093.jpg


PXL_20230105_185530521.jpg


PXL_20230105_193209551.jpg
 
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@FarFire70 To fix this problem, pop rivet a patch panel over most of the hole. Then redrill it further down and over. Use my pic of the ground bolt and the overlapping seam as a reference. You new hole cuts through that seam and the bottom is below the bolt.

And before you do anything, go back and get the rubber insert. Use that to determine the size hole saw you need to use. My memory says it was 3.25".
 
tworley said:
Came here to say the same thing. Dont forget the insert!

Another one with the windstar intake. I think I installed this in 2018? My torque pro app shows ambient air temps being drawn into the intake

View attachment 552479
Click to expand...

Roughly 30° above ambient temp. Insulating the tube and canister and adding more venting to the engine bay will bring the closer to 10° above ambient.
 
I noticed this while digging through pictures. Use the hole saw to make a template by cutting through some thin plywood or cardboard. The slug is your hole size minus the blade thickness. Use this to mark for the pilot bit.

IMG_20130907_153315.jpg
 
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Wildman said:
Sorry to derail your thread for a minute.
Click to expand...

No issue taken. It's a really nice setup!

Wildman said:
Here is one thread about using the Windstar maybe it'll help?

https://www.wranglerforum.com/threads/how-to-install-ford-windstar-intake-on-jeep-tj.2412700/

Another thread

https://www.jeepforum.com/threads/cowl-intake-with-windstar-air-box.566973/
Click to expand...

Yup - reviewed those in my planning. I hadn't realized they went through the 2 spot welds with their hole, whereas I kept mine when I drew up my planned cut...
 
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FarFire70 said:
No issue taken. It's a really nice setup!



Yup - reviewed those in my planning. I hadn't realized they went through the 2 spot welds with their hole, whereas I kept mine when I drew up my planned cut...
Click to expand...

Hopefully you'll get it figured out.
 
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JustDandee said:
Seeing Wildmans post can you space the housing back with short piece of silicone tubing to bridge/ space off the firewall 4”?
Click to expand...

Without cutting a new hole - I think this is the winning move, similar to @SkylinesSuck posted below.

SkylinesSuck said:
I noticed a small rubbing issue with mine. Just had to play with the exact placement including moving it away from the cowl a little exactly as JustDandee mentioned.

View attachment 552439

View attachment 552440

View attachment 552441
Click to expand...

I think this may be the winning move. Thank you for the pics for ideas!
 
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