Intake sleeve... - ZR-1 Net Registry Forums

Paul Workman · 10-16-2011

The plastic accordion-like tube is prone to collapsing at WOT, and the solution has been replacing it with the Samco sleeve, installing wire hoops in the folds of the tube to support it, or installing a metal (aluminum) sleeve liner.

With regard to the sleeve, I made one for myself and a couple others, but they are so simple to make that I thought I'd show you what can be done for under $10 and about an hour's time.

The diagram does not have the dimensions of the sheet metal piece, but you can get that with a tape measure (length) and the width (as I recall) is aprox 17", which allows for ample overlap for final adjustment fitting and riveting (one option) or TIG welding, if you prefer.

You want it to be a snug fit. Pete suggests putting the plastic tube in the oven at about 350 degrees for just a few minutes to soften it up, making it easier to fit over the sleeve for a nice tight fit. (I suppose a heat gun would work in a pinch too.)

The key is to run the sleeve under the lip of the filter housing to add support to that flange, and I found that AFTER snugging the hose clamp to secure the hose to the filter housing AND THEN installing a sheet metal screw through the hose clamp down into the metal sleeve, that it more or less permanently fastens the whole shebang at that end, very nicely. (Some black RTV makes for a really nice, semi-permanent seal.)

Also, cut the sleeve a couple inches short of the air horn end of the accordion tubing. This will allow a little flexing to get the hose over the horn.

Procedure: Take the filter housing and hose as a unit and install the hose to the air horn and clamp it down BEFORE fastening the filter box. Otherwise it is sometimes a bitch to try to get the hose to line up.

Just whatcha need to do on rainy day...Build yourself a sleeve.

P.

Kevin · 10-16-2011

nice write up, I know people used to use coffee cans for this

A26B · 10-16-2011

Nice job Paul!!

WB9MCW · 10-16-2011

Nice write up and drawing Paul.

HAWAIIZR-1 · 10-16-2011

Good stuff P, thanks for sharing!!!

Bob Eyres · 10-17-2011

Mark Coplon used to make them in stainless for $50. Very nice. But your low budjet solution is cool.
I don't think that I would bother to use RTV sealant to permanently mount to the housing though,....overkill.

10-16-2011	#1
Paul Workman Join Date: Nov 2007 Location: Squires (near Ava MO in the Mark Twain N'tl Forest) - Missouri Posts: 6,466	Intake sleeve... The plastic accordion-like tube is prone to collapsing at WOT, and the solution has been replacing it with the Samco sleeve, installing wire hoops in the folds of the tube to support it, or installing a metal (aluminum) sleeve liner. With regard to the sleeve, I made one for myself and a couple others, but they are so simple to make that I thought I'd show you what can be done for under $10 and about an hour's time. The diagram does not have the dimensions of the sheet metal piece, but you can get that with a tape measure (length) and the width (as I recall) is aprox 17", which allows for ample overlap for final adjustment fitting and riveting (one option) or TIG welding, if you prefer. You want it to be a snug fit. Pete suggests putting the plastic tube in the oven at about 350 degrees for just a few minutes to soften it up, making it easier to fit over the sleeve for a nice tight fit. (I suppose a heat gun would work in a pinch too.) The key is to run the sleeve under the lip of the filter housing to add support to that flange, and I found that AFTER snugging the hose clamp to secure the hose to the filter housing AND THEN installing a sheet metal screw through the hose clamp down into the metal sleeve, that it more or less permanently fastens the whole shebang at that end, very nicely. (Some black RTV makes for a really nice, semi-permanent seal.) Also, cut the sleeve a couple inches short of the air horn end of the accordion tubing. This will allow a little flexing to get the hose over the horn. Procedure: Take the filter housing and hose as a unit and install the hose to the air horn and clamp it down BEFORE fastening the filter box. Otherwise it is sometimes a bitch to try to get the hose to line up. Just whatcha need to do on rainy day...Build yourself a sleeve. P.

10-16-2011	#2
Kevin Join Date: Jun 2005 Location: pittsburgh Posts: 4,624	Re: Intake sleeve... nice write up, I know people used to use coffee cans for this __________________ It's not the car, it's the people - Doug Johnson 90 r/r "KEYS ON" nick named "T.L.B"

10-16-2011	#3
A26B Join Date: Dec 2003 Location: Arcadia, OK Posts: 3,392	Re: Intake sleeve... Nice job Paul!! __________________ Jerry Downey JERRYS LT5 GASKETS & PARTS http://www.jerrysgaskets.com 1994 *ZR-1*, Black/Black, Lingenfelter Aerobody, 416cu in, 3.91 gears, coil-over susp, Brembo brakes, etc. 2016 Black-Red, 3LT-Z51 Auto 8-speed.

10-16-2011	#4
WB9MCW Join Date: Dec 2003 Location: McHenry, Il. Posts: 6,584	Re: Intake sleeve... Nice write up and drawing Paul. Last edited by WB9MCW; 10-16-2011 at 05:56 PM.

10-16-2011	#5
HAWAIIZR-1 Join Date: May 2010 Location: Japan Posts: 3,095	Re: Intake sleeve... Good stuff P, thanks for sharing!!! __________________ Craig "ZR-1 NO KA 'OI" "ZR-1 ICHIBAN" 1995 #228 Black/Black with Dunn Heads ZR-1 owner since September 2003 ZR-1 Net Registry Founding Member #0074 NCM Lifetime Member #2048

10-17-2011	#6
Bob Eyres Join Date: Jul 2005 Location: Jupiter, Fl. Posts: 813	Re: Intake sleeve... Mark Coplon used to make them in stainless for $50. Very nice. But your low budjet solution is cool. I don't think that I would bother to use RTV sealant to permanently mount to the housing though,....overkill.