Question about Wayne's book - airbox

s_wilwerding · s_wilwerding's Garage

I'm about to install the airbox popoff valve. I noticed that in order to do so, you need a right-angle drill. As I don't have a right-angle drill, I was thinking I would remove the airbox and drill the hole on a workbench. However, Wayne's book recommends not removing the airbox. Why? It seems like it would make job easier, as well as not allowing any plastic chips to be sucked into the engine.

As a follow-up request, how difficult is it to remove the airbox? I've heard you have to remove it to change the spark plugs, which I'll probably do if I have the airbox off.

Thanks.

Targa77 · Targa77's Garage

I have heard that it is a pain to remove the box without a partial engine drop. Some guys have removed these without problems but I don't think that I'm ready to tackle that one yet. You should not have to remove the box to install spark plugs.

Wayne 962 · Wayne 962's Garage

Big pain, but doable. Frankly, if you take the box off, you will later regret not simply buying a right angle drill from Home Depot for $40...

-Wayne

scottb · 08-30-2002, 08:08 AM

Harbor Freight sells a right angle attachment for a conventional drill. It's only $25.

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=43623

Good luck!

Superman · 08-30-2002, 08:22 AM

I have the HF right-angle drill attachment (heck, I have most of the items HF sells) and I've used it several times, and it works okay, but it becomes a two-handed drill. A one-handed unit would be easier and I think there are pneumatic right-angle drills that would perform better. My popoff was installed with the HF attachment though, and it works just fine. WAY WAY WAY easier than removing the air box. WAY easier. A shop vac cleans up most of the plastic shavings. The rest will just provide a protective coating inside your exhaust. A little plastic is not going to hurt your engine.

Be sure to rough up the popoff valve mating surface. It is a very smooth plastic that your high-temp epoxy may not bond well to unless you take a little fine sandpaper to it. My popoff popped out after installation, leaving all the dried epoxy on the air box, none on the valve. I sanded, reinstalled and have had no more trouble.

Doug Zielke · 08-30-2002, 08:30 AM

Steve,
When I did mine, I rented a nifty little Makita right-angle drill for $10 a day. The box is a PITA to remove with motor in the car.

A few extra tips:

-Make sure the drill you do use, has a chuck which will take the shank of the holesaw arbor.

- Drill a 1/4" pilot hole *first*. Don't hit the box hard with a punch to mark the drilling spot, or the box may crack.

- The large hole saw will want to grab the box in a vicious manner! Proceed with caution! Do not force the saw! Be prepared for it to grab as it breaks through the box floor.

- Vac up all the chips you can, but don't worry about the ones you can't. Your motor will safely "eat" a bit of plastic!

s_wilwerding · s_wilwerding's Garage

I appreciate everyone's comments.

I'll probably head out to HF this afternoon and pick up a right-angle drill - they look like they'll work well.

With any luck, the installation will go easily and the car will be back in service by Monday.

Thanks again.