Tools

ABS FWI By Ryan Martinez (Clubgp name johndeerrm)

Works for GTP not tested on GT's or GTP's with intercooler

ABSOLUTELY DO NOT DRIVE THROUGH STANDING WATER WITH THIS INTAKE. IF YOU LIVE IN A RAINY CLIMATE YOU MAY WANT TO INSTALL SOME TYPE OF SHIELDING AROUND THE FILTER. I AM NOT TO BE HELD RESPONSIBLE FOR DAMAGE DUE TO WATER INTAKE. DO EVERYTHING AT YOUR OWN RISK.

Tools: (Bold items are click able)
Saw
Sander (vibrational or some type or mounted belt sander)
Philips screw driver
10MM socket
Dremel rotary Tool
Dremel Cutting disk (Cutoff wheel #426 with mandrel #402)
Dremel High speed cutter (Dremel #115)
Measuring tape (I found the type that is used for sewing worked pretty well as it is pliable for measuring around bends)
Pencil
Drill and 1/2" bit
Anything I forgot about

Materials: Click here for a picture of the materials
14.75 inches of 3" ABS pipe
1x 90 Degree ABS elbow
1x 45 Degree ABS elbow
3" Black rubber coupler
7" or 9" K&N Cone filter
ABS Cement
Spray paint (optional)
Sand paper

Directions. (Bold items are click able)

Remove existing intake
Remove driver side wheel
Remove fender lining
Remove driver side headlight
Unbolt and bend the brace that goes from fender to frame
Measure out and cut a 14.75 inch section of the ABS pipe
Measure and cut the 45 degree bend, To get the angle correct you will need to measure on the line that is in the plastic on the inner most and outermost part of the bend, on the outside make a mark at 4.5 inches from the end and on the inside make a mark 2.5 inches from the end. Then wrap the measuring tape around half of the pipe and draw a line between the two marks, repeat for the other side. (See the line in the plastic here)
Cut on the line you just made, it wont turn out perfect because of the bend and the roundness of the elbow. Make sure you don't cut to much off, You will then want to take the dremel with the cutoff wheel and remove any remaining material that you missed. Now use your power sander to make sure the cut is completely flat. You can check flatness by putting it on a counter top and shining a light on the inside of the pipe, if you see light then you need to do more sanding.
Sand each end of the ABS pipe and check for flatness using the method described above. If the cuts are not exactly square that is ok as long as its only a few degree's off.
Sand the small end of the 90 degree bend and check for flatness.
Using the ABS cement lightly coat one end of the abs pipe and place the 45 degree elbow on it (sanded edge gets glued). Move quickly as the cement dries fast. Align the pieces making sure the inside is smooth with no lip on the joint. If cement squeezed out of the joint on the inside you will want to smooth it out with your finger (move quickly).
You will now need to bend the fender wall to make clearance for the pipe.
Paint the outside of the joint with the abs cement, try to make it as smooth as possible (in 10 min or so you can sand it down if you want)
On the outside center line of the 45 degree elbow you will want to draw a line all the way down the pipe.
Hold the pipe with the 45 degree elbow facing away from you and measure 1.5 inches to the left of the centerline and make a mark. Line this mark up with the centerline on the 90 degree elbow. You may want to line it up then tape the joint and test fit it with the filter on before you glue it.
Glue the parts together using the same method used on the other end.
(optional) Sand the pipe down and sand all joints, then Tape off any parts that will come in contact with the rubber couplers including the one on the filter. Now you can do your painting.
Take the 3" rubber coupler and drill a 1/2" hole in it, make sure there is room for the pipe to fit in the coupler as far as it will go without hitting the IAT sensor.
Install fender barrier (triangular piece of plastic that separates the engine compartment and the fender) on intake then install intake into fender. make sure all hose clamps are tight.
Put the fender lining back on.
Install IAT sensor.
Reinstall the headlight
Put wheel on.
Torque lug nuts to 100ftlbs.
Enjoy your brand new FWI.