R.J. SEESE DISCLAIMER

    I do not have the credentials to offer automotive advice.  The modification experiences that follow, and any I might offer on this web site in the future, explain how I chose to approach a modification I wanted to make to my personal car.  I am not suggesting that anyone else make this modification to his or her vehicle.  In the event anyone chooses to accept the responsibility of initiating a similar vehicle modification, they should do so with the understanding it could result in undesired damage to their vehicle and could void the warrantee provided by the vehicle manufacturer.  In addition, I wish to point out that undertaking any vehicle modification without proper knowledge, experience, tools, and safety equipment can result in personal injury.   

AIR FILTER HOUSING MODIFICATION
By Robert J. Seese

APPLICATION: 
My car is a 1996 Mustang V-6 coupe.  You will find a near identical air filter system on other Mustang V-6 and V-8 vehicles.    

 

TOOLS REQUIRED:  
Usual mechanical tools plus a basic Dremel tool.  The Dremel variable speed tool and its variety of accessory bits has proven indispensable for many of the modifications I have made to my 3.8 Mustang.  

 

TIME REQUIRED:
A project that took me about three hours.

 

COST OF THIS PROJECT: 
You must purchase a permanent K&N air filter #91L118.  The cost varies, but it will be around $50.  You might as well buy the cleaner and spray "recharging" kit also because you will need it to service the filter.  That runs another nine bucks or so.

 

WHERE TO GET THE PARTS:
I purchased my K&N filter and service kit from a local auto parts store.  

 

WHY MAKE THIS MODIFICATION?
My goal was to enhance vehicle performance by improving the ability of my 3.8 engine to inhale air.  When I made this modification, the $150 to $200 induction and ram-air type kits now featured in many Mustang performance catalogs were just becoming available for the 3.8.  However, I question that installing one of these expensive kits would have accomplished much more than my far lower cost "driveway" modification.  

 

WHAT I ACCOMPLISHED:  
This modification achieved a just noticeable improvement in performance.  My guess would be that my 3.8 gained around three horsepower.  I also noticed a little more aggressive engine sound and I think the modification looks quite impressive.  Finally, I see getting more air to the engine as a necessary first step to gain maximum results from any future engine performance modifications.     

 

PHOTOS: 

 

1.  The stock air housing, the air silencer, and the K&N filter

 

2.  The finished modification  

 

HOW I COMPLETED THE MODIFICATION:
I removed the filter housing retaining bolt and unlatched the filter housing from the MAS air assembly allowing the housing to drop out of the bottom holding tab.  I then lifted the housing from the lower isolator mounts and removed it from the engine compartment.  I next removed the stock air filter and discarded it.  Last, I removed the air silencer from the right fender apron and discarded it (good riddance).   

I decided that having gone this far, I might as well modify the filter housing to minimize its interference with getting air to the filter.  I started by measuring and laying out a "cut-line" with chalk and then removed only the tip of the cone-shaped housing using the Dremel tool fitted with a cutting wheel (don't forget the full coverage eye protection). 

I reinstalled the system using the K&N filter and went for a ride.  There was improvement in performance and no derogatory indications.  I removed the air filter housing again and this time I cut away as much of the housing material as possible without compromising its integrity or fastening system (this is where the Dremel tool becomes indispensable).  I then hand-sanded the edges of all cuts to achieve a professional look and sprayed the housing heatproof silver.