Well fellas, after a long weekend, the 6637 project has finally reached completion. Turned out pretty well for the whole $50 I have into it (filter included). Lots of time test fitting and trimming down my PVC pieces though. Also had a chance to put a better bushing in my CDR block off and RTV the hell out of the intake hat. Hopefully it works this time!
At first I bought a 4 to 3 reducer to fit the filter and bought my 90* and two 45* fittings that would fit the 3ft section of 3" PVC I had.
When I went to slide on my reducer, I realized since I had drain pipe PVC, the reducer was WAY too large! Tossing that aside, I figured I would slip in the 90* elbow to see how far off I was...it fit perfectly without a reducer to the filter at all. Good deal, just threw on a hose clamp and started fitting the rest of the pipe.
My FINAL fitment resulted in my 3ft section cut down into 4", 12" and finally 5" sections routing from the turbo out to the filter. With some grease I managed to get the rubber 90* elbow on the turbo boot to slip over the pipe, but it was flared out pretty badly. Took that 4" section over to the grinder and notched about an inch in for a better fit without the flare.
After that, it was simply getting the right angles to miss injector lines and the power steering pump while still allowing enough room to slide the 90* fitting out of the filter to be able to service it. Made a simple bolt-strap that fastens to the mount for the old battery tray to keep the filter from rolling around as well.
Finally got everything where I wanted it, slipped the old pair of my wife's ***** hose over the filter and bolted it all down. I also put some black RTV around the joints to make sure everything is air tight.
Picture time!
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I have to say, everything looks GOOD so far! I did a couple of water tests with the filter wrapped in trash bags and didn't notice any leaks getting inside the fender. I'll have to see what happens in real world situations though and report back.
My test drive tonight revealed about 100* cooler EGTs and a bit more turbo whistle. Snappier throttle too!
Thanks guys for keeping up with me on this project and I hope the few of you that contacted me will consider doing this too!
-Dave