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Snorkel fitted.....
Well, I decided to bite the bullet and drill some large holes in my pride and joy yesterday. Got a mate to help, and double check every measurement with me.
Better safe than sorry!!
Made a nice early start. Removed the air filter box, and the bit of pipe that heads off down towards the headlight. Nice bit of working room in the engine bay, once that lot's gone! (First pic) You also have to remove the plastic wheel arch lining, to get at the bolts later..
Next, the template was taped onto the outside of the front wing, making sure it was lined up with the top edge, by the bonnet, and also the rear edge, by the passenger door. Holes were marked through the template, and the template then removed... (Second pic)
Now it got scary. The first damage was done when the five holes were centrepunched. (Four mounting holes, and one for the airway). no going back...
All five were pilot drilled, then I got busy with the 83mm holesaw. (pic 3) Actually, that's my mate in the pic, but he was just posing for the camera. I can assure you he didn't want to be the one to drill a sodding big hole in my truck! (Pic 4)
The snorkel comes with a couple of strengthening plates, so that when you drill an 89mm hole in the inner wing, the plates go around the hole, to restore any strength. One of these plates was used to mark the inner wing hole, and then that was drilled out. (Pic5). As the Safari snorkel is not specifically designed for a gen 2 Surf, there already is a built in strengthening brace around where these plates go, so I had to cut about a quarter of the outer support plate away, to fit around the brace. The next two pics show the support plates, from the inside and the outside..
The mounting holes were drilled the correct size (actually, the instructions said to open them up to 16mm, but I only had a 13mm drill, so that's the size they got drilled to!) They are oversize to allow for a bit of movement.
The snorkel can then be offered up to the truck, and the 'A' pillar marked for the securing bracket. Then the pillar needs to be drilled...... (Two pics, one of the holes, one with the bracket fitted)
Than it was just a case of bolting it all up tight. Bit fiddly to get at the bolts inside the inner wing, but a bit of perserverance (?) it can be done.
Bolt the top air intake on, and replace the inner wheel arch lining.
The rubber pipe hat comes with the snorkel isn't quite right for the 2.4 airfilter box, but it was easily adapted by cutting about 1/2 inch off it's length, and also a little crescent out of the bottom, to enable it to fit on to the air inlet pipe. Jubilee clipped all up, and job done!!! (last pics).
I love it, and am looking forward to the next floods!!!!!
As a test, I went out this morning, took the top off the snorkel, started the truck, and put my hand over the intake pipe. The rubber pipes got sucked in on themselves, and it nearly stalled, due to lack of air (I took my hand away to stop it stalling). I'd say this proves there's no major leaks on the inlet airways..
What do you think?
Better safe than sorry!!Made a nice early start. Removed the air filter box, and the bit of pipe that heads off down towards the headlight. Nice bit of working room in the engine bay, once that lot's gone! (First pic) You also have to remove the plastic wheel arch lining, to get at the bolts later..
Next, the template was taped onto the outside of the front wing, making sure it was lined up with the top edge, by the bonnet, and also the rear edge, by the passenger door. Holes were marked through the template, and the template then removed... (Second pic)
Now it got scary. The first damage was done when the five holes were centrepunched. (Four mounting holes, and one for the airway). no going back...
All five were pilot drilled, then I got busy with the 83mm holesaw. (pic 3) Actually, that's my mate in the pic, but he was just posing for the camera. I can assure you he didn't want to be the one to drill a sodding big hole in my truck! (Pic 4)
The snorkel comes with a couple of strengthening plates, so that when you drill an 89mm hole in the inner wing, the plates go around the hole, to restore any strength. One of these plates was used to mark the inner wing hole, and then that was drilled out. (Pic5). As the Safari snorkel is not specifically designed for a gen 2 Surf, there already is a built in strengthening brace around where these plates go, so I had to cut about a quarter of the outer support plate away, to fit around the brace. The next two pics show the support plates, from the inside and the outside..
The mounting holes were drilled the correct size (actually, the instructions said to open them up to 16mm, but I only had a 13mm drill, so that's the size they got drilled to!) They are oversize to allow for a bit of movement.
The snorkel can then be offered up to the truck, and the 'A' pillar marked for the securing bracket. Then the pillar needs to be drilled...... (Two pics, one of the holes, one with the bracket fitted)
Than it was just a case of bolting it all up tight. Bit fiddly to get at the bolts inside the inner wing, but a bit of perserverance (?) it can be done.
Bolt the top air intake on, and replace the inner wheel arch lining.
The rubber pipe hat comes with the snorkel isn't quite right for the 2.4 airfilter box, but it was easily adapted by cutting about 1/2 inch off it's length, and also a little crescent out of the bottom, to enable it to fit on to the air inlet pipe. Jubilee clipped all up, and job done!!! (last pics).
I love it, and am looking forward to the next floods!!!!!
As a test, I went out this morning, took the top off the snorkel, started the truck, and put my hand over the intake pipe. The rubber pipes got sucked in on themselves, and it nearly stalled, due to lack of air (I took my hand away to stop it stalling). I'd say this proves there's no major leaks on the inlet airways..
What do you think?
dunno if i have the bottle to cut into my surf
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