DIY K&N Air Filter Housing
The C6 Corvette OEM air filter is mounted right above the radiator shroud and only gets hot air from the engine compartment.
Most after market Cold Air Induction (CAI) kits require cutting a hole in the top of the radiator shroud to get access to cooler outside air. However, the K & N kit made with carbon fiber does not.
The first step in the modification is to cut an opening approximately 6” by 15” inches in the radiator shroud directly below the K&N filter assembly to give it access to cooler air. But the cooler air will flow directly into the engine compartment and by-pass the A/C condenser and radiator. The solution is build a new filter housing around the filter yet leave the attractive carbon fiber top exposed on the K & N filter.
I removed the OEM shroud from the car to cut the opening but this is not necessary.
WARNING: If you cut the shroud in the car, cover the A/C condenser with a piece of plywood or sheet metal to prevent putting a hole in the expensive A/C condenser with the utility knife. The odds are vitually 100% the knife will slip and put a hole in the A/C condenser.
Most after market Cold Air Induction (CAI) kits require cutting a hole in the top of the radiator shroud to get access to cooler outside air. However, the K & N kit made with carbon fiber does not.
The first step in the modification is to cut an opening approximately 6” by 15” inches in the radiator shroud directly below the K&N filter assembly to give it access to cooler air. But the cooler air will flow directly into the engine compartment and by-pass the A/C condenser and radiator. The solution is build a new filter housing around the filter yet leave the attractive carbon fiber top exposed on the K & N filter.
I removed the OEM shroud from the car to cut the opening but this is not necessary.
WARNING: If you cut the shroud in the car, cover the A/C condenser with a piece of plywood or sheet metal to prevent putting a hole in the expensive A/C condenser with the utility knife. The odds are vitually 100% the knife will slip and put a hole in the A/C condenser.
First, after careful measurements are made, a paper template is created and assembled using masking tape. This is a trial and error process and may require multiple version before the design is finalized.
Using the paper template, cut the waste basket bottom with a utility knife to make the two corners of the filter housing. Since the waste basket bottom was too narrow for the K&N filter, new top and bottom pieces needed to be fabricated.
The new filter housing was made using a black plastic kitchen waste basket purchased at the local home improvement store. It is molded polyethylene plastic or the same material as the OEM shroud so it will blend in and look almost like factory.
From the paper template, a utility knife was used to cut the waste basket to form the ends of the new filter housing and bottom lip that attaches to the OEM shroud.
1) The waste basket bottom had the right shape to form the ends of the filter housing but was too narrow so it was cut to form the two corners.
2) A strip 2" wide x 5" long was cut to connect the two half and fill the gap by the hood. Contact cement or hot glue was used to attach the various pieces.
3) Then the bottom piece was formed from a strip 4" wide x 23" inches long is attached to the filter housing to the OEM shroud with 3M Heavy Duty double sided tape available at the local home supply store.
3M double sided tape was used to attach the new filter housing to the OEM shroud. For the tape to stick properly, thoroughly wash the contact area with cleaning solution. Then wipe it down with denatured alcohol to remove oil, silicone remaining. Scuff it with medium grit sandpaper or Scotch Bright then wipe it again with alcohol. Don't use ANYTHING else but alcohol because it WILL leave a residue and the tape will not stick.
Once the tape is stuck, it should not move. If it does, the surface was not clean. It takes 24 hours for the tape to reach full strength. An alternative is contact cement but both surfaces must fit perfectly with no gaps. An alternative is to use the plastic push pins available at any automotive supply store.
Optionally, remaining gaps between the new filter housing and the OEM shroud can be filled with black caulk. I tried Silicone caulk from the local home improvement store but it does not stick to the slick polyethylene so I may try RTV or black sealant sold at the automotive stores for sealing glass. In any case, this really is not necessary.
From the paper template, a utility knife was used to cut the waste basket to form the ends of the new filter housing and bottom lip that attaches to the OEM shroud.
1) The waste basket bottom had the right shape to form the ends of the filter housing but was too narrow so it was cut to form the two corners.
2) A strip 2" wide x 5" long was cut to connect the two half and fill the gap by the hood. Contact cement or hot glue was used to attach the various pieces.
3) Then the bottom piece was formed from a strip 4" wide x 23" inches long is attached to the filter housing to the OEM shroud with 3M Heavy Duty double sided tape available at the local home supply store.
3M double sided tape was used to attach the new filter housing to the OEM shroud. For the tape to stick properly, thoroughly wash the contact area with cleaning solution. Then wipe it down with denatured alcohol to remove oil, silicone remaining. Scuff it with medium grit sandpaper or Scotch Bright then wipe it again with alcohol. Don't use ANYTHING else but alcohol because it WILL leave a residue and the tape will not stick.
Once the tape is stuck, it should not move. If it does, the surface was not clean. It takes 24 hours for the tape to reach full strength. An alternative is contact cement but both surfaces must fit perfectly with no gaps. An alternative is to use the plastic push pins available at any automotive supply store.
Optionally, remaining gaps between the new filter housing and the OEM shroud can be filled with black caulk. I tried Silicone caulk from the local home improvement store but it does not stick to the slick polyethylene so I may try RTV or black sealant sold at the automotive stores for sealing glass. In any case, this really is not necessary.
Below is a picture of the kitchen waste basket before cutting it apart. I needed 2.
Here is the first can cut. It is the passengers side.
Below is the passenger's side done except for some minor final trimming.
This is the right and left pieces glued together. The bottom piece is cut and fitted prior to install.
Finished DIY K&N Filter shroud.
