505 Cold Air Box GB

[Circuit]

Circuit, get us some pics of what the issues are... and Rich, can you duplicate his pics with your install so we see what it should be like?

I may not have my box for a while yet being in Canada

The cutout doesn't account for the P5 turn signal and high beam bulge in the back of the headlight.

 

[Installshield 2]

ok, so we just need to make that cut out slightly bigger? I'd be happy to do this stuff and draw something up for any P5 owners on what to cut, i just won't have my car back until after work today. I haven't even tried to set the box in yet, so this was news to me, too...

But any P5 owners...I briefly talked to rich, which i'm sure the rest of you have...this thing is aluminum...honestly, it'll cut like butter with just a simple rotary tool...If we can come up with a good template that you could print and lay over the sidewall, there is pretty much no chance of screwing anything up...and from what i can tell, this modification will be completely hidden from view by the top plate, right?

 

[i12drivemyMP5]

Started my install this morning, I will button things up this Friday. So far so good, this piece is tits! THANK YOU RICH!

That looks so clean! Was thinking raw but diggin the black seeing it installed..........

The cutout doesn't account for the P5 turn signal and high beam bulge in the back of the headlight.

OK, this is what I wanted to see. But looks like minor adjustment for those already sent out, as has been stated, if it doesn't open up the filter area to do so. Wasn't sure before but this is turning into want....install pics are selling it too. Lotta irons in the fire at the moment, will these be available for awhile?

 

[Installshield 2]

^yeah its just going to open up the front of the box slightly, which isn't going to let any more hot engine bay air in for the most part...it just needs a 'deeper' half circle sliced out to fit around the back of the P5 head lights it seems...Even if that whole forward section needs lanced, its not going to hurt function or even the look of it from what i can tell...again, all this will be 100% hidden by the upper plate...

I'll guinea pig this tonight, and update with LOTS of pics...its just a matter of when i get my car back from the inspection station...

EDIT: spoke with rich again, he'll have a housing to work with by the weekend. I'll still get some measurements and pictures on here when i get in there to get a better idea of what we're up against...I may hold out on cutting though for the time being until we hear what the best option is...

 

[dmention7]

So, I'm sure this will probably be retardedly apparent when I go to install mine, but I take it for the MSP kits that the MAFS fits inside the box, and the filter attaches directly to it? And if at some point I end up relocating the MAFS, I can just dig up a longer 3" filter to attach directly to the pipe in the box, right?

I may or may not have almost had a queen derp moment when I was wondering wtf that extra reducing coupler was for, and why the filter didn't fit on the pipe in the box

 

[bwalt]

Damn, I have P5 headlights in my MSP.

 

[Installshield 2]

I didn't get my car back until this morning, but now have it...i'm done with work in about 2 hours, and i'll start looking at this more then...

Just looking over my box last night; it looks like about an inch of material needs to be removed in order to slide in under the P5 head lights...after that, you'll probably be able to even reuse the rubber trim that presses over the lip...

I wasn't fully seeing where the problem was from pictures on here, as i thought the box fit along the head lights...but the front of the box slides underneath the lights towards the front bumper...and its the upper cut out that needs to be enlarged a little...seems very straight forward...

 

[callphy]

i received mine today XD

but i guess i am gonna ask shop to separate and weld my clutch line bracket while replacing it with ss clutch line and 4 brake lines first

(gonna replace driver side engine mount, thats y i might need clutch bracket rewelded to the chassis)

dont wanna dmg the box, i would try to see if theres fitment issue in few days.

 

[505zoom]

P5 headlight gets here monday. Huge thanks to Circuit and Installshield 2 for being so cool and helping me out with this situation.

 

[505zoom]

So, I'm sure this will probably be retardedly apparent when I go to install mine, but I take it for the MSP kits that the MAFS fits inside the box, and the filter attaches directly to it? And if at some point I end up relocating the MAFS, I can just dig up a longer 3" filter to attach directly to the pipe in the box, right?
)

That is 100% correct.

 

[505zoom]

Damn, I have P5 headlights in my MSP.

I am just doing the option of

a) template to cut the existing box

or

b) refund

That's all I can do at this point.


Again I am super sorry about the headlight... It honestly never crossed my mind but should have.

 

[bwalt]

Rich, I wont have an issue working the box to fit my headlights. Now I'm really glad I didn't get it coated.

 

[ScratchNSniff]

Shipped out a driverside headlight on Friday morning guys for measurements...should be arriving Monday...

 

[sleepwalker]

I am just doing the option of
a) template to cut the existing box
or
b) refund
That's all I can do at this point.

Again I am super sorry about the headlight... It honestly never crossed my mind but should have.

It's things like this, consistently, everywhere I see you on this board, that make me think you're a king when it comes to taking care of customers. All I can say is, don't worry so much about it. You're making 100% customized parts for a range of cars that never had this kind of equipment before; little things like this are bound to happen. And you're addressing the issue in top-notch fashion. I suspect that the few folks that are having the issue are all supercool about it, and are perfectly happy to work together with you to solve it. Your posts since the discovery have a shade of panic and self-butt-kicking (and I see it because I do the exact same thing to myself) and I really think it's unnecessary. You've made an amazingly awesome product that is making a lot of people happy, and a few of them need a slight tweaking to be perfect. As far as I can tell, you've got a 100% success rate with this thing. So don't panic and don't self-punish. Put on a grin and be proud. You're kicking ass.

All that being said - if I can get the scratch together by a week from this Wednesday, I might really like to pick one of these up. If the remaining available stock is depleted, is there a possibility of another run being done soon?

 

[Installshield 2]

I have my full NA system now installed on a P5, and car is running exceptionally well...i went to this system from a stock intake with a drop in K&N, twiggy cams, Mp3 computer, Mazdaspeed header, and RB cat back with custom mid pipe...throttle response is outrageous, and the sound with these cams...it really seems like a different car...

Please wait for Rich's template (I'd be happy to give feedback with that rich when you start playing around with it). I spent a good 3 hours back and forth slowly making adjustments to the box sidewall, but now knowing exactly what needs removed...i could do it literally in less than 30 minutes. I just used a 5 speed dremel with a cutting wheel and a stainless 'bar bur' to finish smoothing the edge...the rubber trim still fits perfectly...from the engine bay; you'd never know i had to do anything...i'm not perfectly finished, but have it close enough to fit everything and do a few test drives...

so to anyone worried about taking this on, don't be...my gf could've done it...and its an area so hidden, you'd never be able to tell...

some pics of it installed...i had the car parked in 90 plus degree sunlight, and my plexi glass epoxy let loose...so the top is now sitting downstairs with a fresh bead of high temp gasket maker, and a few clamps...i'm sure that'll hold the glass on fine, and i was probably just unlucky with that...easy fix if you run into it, though...

https://docs.google.com/file/d/0B9wG_iZEqPQNb1l2Vjl2a2xLRkE/edit?usp=sharing

https://docs.google.com/file/d/0B9wG_iZEqPQNUk11U0Q1cU11eFU/edit?usp=sharing

https://docs.google.com/file/d/0B9wG_iZEqPQNZjZNaFU1S0FNcDg/edit?usp=sharing

sorry about the bad lighting, and again, this was only a test fit to make sure everything fit ok...i'm going to run that coolant line under the maf to hide it, and do some more work on the stock reservoir bracket and mounting location...i need to trim it a little, as you can see from one of the pics...but it easily fits in front of the battery on the remaining stud from the stock intake...i just had to drill one of the holds out about 1mm to fit it over that exposed stud...and used the same 10mm nut to tighten it down...

and Rich, exactly what sleepwalker said...you offered by far the greatest intake system that ever became available for these cars...some slight modification to a completely custom designed limited run product is completely ok imo, and i'm sure others...when people see how little work is involved, there won't be any issues...Couldn't be happier with this thing man, one of my favorite mods so far...and i've been messing with this thing for 11 years haha.

 

[i12drivemyMP5]

I have oil catch can and coolant overflow that would have to be relocated but by the looks of things in your pics, my ballast for HID on that side could just stay where it is now. The trimmage to fit around headlight is not what concerns me. My question would be....do the 2 rubber 90 degree elbows give enough flex for motor movement?

 

[Installshield 2]

^the couplers are pretty flexible...once i had it clamped to the throttle body, i tested to see how much movement and was pretty surprised (especially how stiff they seem when putting them on the aluminum piping)...i've put about 50 miles on the car with the system 'test fit', and didn't notice any issues at all...i'll leave it like this until i have to remove it for a clutch install sometime this month, then get it seated a little better...

granted, i'm on the stiffest AWR mounts available, so my drivetrain doesn't move a whole lot...but there does seem to be an ok amount of play there if you need it...

 

[Installshield 2]

put the lid on this morning, the glass seems to be holding perfectly fine. Loved every minute of the drive here to work.

i used some left over red RTV valve cover gasket maker...just ran a bead over the existing epoxy stuff, and clamped it over night...pushed pretty hard on it before i installed it, and i didn't seem close to breaking loose...So if anyone else runs into that issue, its very easy to fix...

 

[bwalt]

Finally picked up my box after it had been sitting at the post office for over a week. Excellent packaging as always, Rich. I'll have installed pics up after I re-arrange some things under the hood to make this all fit.

 

[Mazdaspeed2oo35]

Finally today i have receive my box.. all i can say its ******* awesome. No words to describe how satisfied i feel. It has been worth every second ive waited for it. s*** looks massive.. will post pictures...