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Old 11-18-2018, 05:17 PM   #1
19boneatock88
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Location: Glenville WV
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Stealth intake for 03-04 ION

I finished my next mod and since it doesn’t strictly apply to engine efficiency I wanted to make a new thread for it...

Basically anyone that has an 03-04 ION knows about the oval airbox outlet and most people who want an intake tend to just delete the airbox all together and do either a short ram or full CAI...

I decided to keep the airbox setup because a true CAI isn’t cheap and a short ram draws warm air from the engine bay, making less power...

I used a rotary tool to cut the tiny oval outlet off the airbox lid and then enlarged the hole to accommodate a piece of 3” IPS HDPE pipe, which has an outer diameter of 3.5”, and still has an inner diameter of well over 3”... I suppose you could use 3.5” exhaust tubing but IMO it wouldn’t appear as stealthy and joining metal to plastic could be more troublesome...

Since it seems a 3” CAI is sufficient for the Redlines to make up to and above 300whp I’m guessing the new lid will flow all the air an L61 should ever need, and it still utilizes the cold air draw of the factory airbox...

Maybe also, necking down the intake to 3” after the airbox and down into the TB will raise velocity a little for better torque...

After having made the first one I guess it would take me about 90 min to reproduce the design if there was interest...
Attached Images
File Type: jpg DD2AB808-9A9D-441D-809E-C03984F14463.jpg (113.2 KB, 17 views)
File Type: jpg 1BC12466-E46A-4F10-B0BA-E25829816D2A.jpg (110.3 KB, 17 views)

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 10-14-2019, 01:40 AM   #2
19boneatock88
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Join Date: Sep 2018
Location: Glenville WV
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: Stealth intake for 03-04 ION

I wanted to update this, as I’ve installed the new air box lid, as well as opening up the inlet in the bottom of the air box base itself... more power? I’ve no idea to be honest

I’ll upload pics as soon as the forum will let me?

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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Old 10-22-2019, 11:42 AM   #3
WrightMan
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2004 ION-2 Sedan
Default Re: Stealth intake for 03-04 ION

I decided this was cleaner but the intake section inside the wheel well was a pain to get out and is very restrictive I think or at least overly complicated.
Attached Images
File Type: jpg Resized_20190711_201605.jpg (128.5 KB, 6 views)

...
2004 Saturn Ion AEM CAI, Aftermarket Head and Taillights, ZZP 2.5" Cat and Custom 2.5" Complete Exhaust
2000 F150 Off-Road 3" Duals and K&N Intake SCT Livewire Tuner
2013 Escape 2.0T AWD CAI

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Old 10-23-2019, 11:18 PM   #4
19boneatock88
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Location: Glenville WV
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: Stealth intake for 03-04 ION

Since the iOS 13 update comes with a built in image resizer I can actually post pics of my intake setup lol

Yeah the stock setup is fairly restrictive, I haven’t got that problem with my 3.5” airbox outlet and enlarged lower inlet, it still looks fairly stock, except I gotta redo the lid again, guess who used the wrong glue for the application? This guy...
Attached Images
File Type: jpeg 9BBCCA29-F124-4AAC-A29C-F097FC01061D.jpeg (88.6 KB, 4 views)
File Type: jpeg D9E24CC7-7EBA-4A5F-9B08-2AF82EA11E54.jpeg (92.2 KB, 5 views)

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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Old 10-26-2019, 01:18 PM   #5
WrightMan
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2004 ION-2 Sedan
Default Re: Stealth intake for 03-04 ION

The intake parts you don't see are crazy. Taking these out and just having an elbow might help as well.
Attached Images
File Type: jpg Resized_20191023_202931.jpg (68.2 KB, 3 views)
File Type: jpg Resized_20191023_203015.jpg (98.2 KB, 3 views)
File Type: jpg Resized_20191023_203029.jpg (105.6 KB, 4 views)

...
2004 Saturn Ion AEM CAI, Aftermarket Head and Taillights, ZZP 2.5" Cat and Custom 2.5" Complete Exhaust
2000 F150 Off-Road 3" Duals and K&N Intake SCT Livewire Tuner
2013 Escape 2.0T AWD CAI

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Old 10-30-2019, 01:37 AM   #6
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: Stealth intake for 03-04 ION

Those are long since gone on my car, they came out while I had the fender off the first time lol

Weight reduction!

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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