Homemade Intake Horn

[Relentless70]

I am in the process of making my own intake horn. I'm too cheap to buy one, and I have the materials, the time, and the equipment to do it. I will also temporarily eliminate the grid heater until September or October. The intake tube will be 3" OD, made from driveshaft tubing from a 1985 Dodge 3/4 ton truck. The first pic is the flange that bolts directly to the intake manifold. The center hole in the flange is to make it easier for me to torch out the 3" circle......it gives me an easy starting point.

[Relentless70]

The driveshaft is necked down to nearly the same size as my existing intercooler tube, which means I won't need to buy a rubber boot.

[Relentless70]

I welded on a 4" long piece of 3" pipe to the flange. I'll end up cutting some of it off.....better safe than sorry .

[Relentless70]

Cleaned up the weld somewhat, and used a wirewheel to blow off the rust. I'll have more pics tomorrow .

[anoldbiker]

I like this. Always better if you can form fit it yourself. Not sure of the year truck you have, but I've read on mine I can max the ID up to 3.5". Not for yours ?Are you going to get this powered coated ?

[Rogan]

looking good, relentless!

[Relentless70]

I like this. Always better if you can form fit it yourself. Not sure of the year truck you have, but I've read on mine I can max the ID up to 3.5". Not for yours ? Are you going to get this powered coated ?

I'm not gonna powder coat it, but I'll shoot some flat black paint on it

[Relentless70]

After triple-checking some measurements, I ended up cutting off 3 inches of the tube. I have 2 segments welded to the flange now.

[Relentless70]

Here is a pic of the unit with the welds cleaned up, inside and out. I'm thinking of cutting the angles shallower, 'cause I don't like those sharp bends it is making. It will require more cutting and welding, but its all good

[ISX]

You just had to do this didn't you :banghead: Now I want to relocate mine completely out of the way. I do like what you have done though

[Relentless70]

Added 2 more segments cut at 4.5 degrees per end, short side cut at 9/16". I'm liking the radius that developing now .

[Relentless70]

Welds cleaned up here.

[Rogan]

what's the INSIDE of that jewel look like? ;)

[Relentless70]

Sorry for the delay in replying. Here is a pic of the inside of the tube so far. I'm not done smoothing it out yet.

[Mopar1973Man]

Little Bondo and paint and no one would know...

[Relentless70]

Added 2 more segments to the tube. I'm not gonna post anymore pics until the unit is done.....no need to bore you guys with the small stuff. I hope to have it finished by the end of this weekend

[Macarena Man]

Interesting project, looking forward to seeing more of it ......

[Mopar1973Man]

Insider information... Relentless70 already told me he's not going to post anything more till he completes the intake now... So keep checking back he'll posted up soon when he finishes the intake horn... Look back a post or two...

[Relentless70]

I finally finished the intake horn.....good lord I hate grinding lol......all that is left to do is cut my output side intercooler tube to the correct length and install the intake horn . I hope to be able to get it all done tomorrow.

[Rogan]

Looks great!!