cheap xj snorkel
 

here is how i'm making my cheap xj snorkel


items needed

qty description

1 90 deg rubber elbow
2 45 deg rubber elbow
1 3" snorkel head
1 1.5m section of 3" Al tube ( this will be cut in to sections)
2 m6 nutserts
2 m6 x25 screws
1 40x3x60 mm AL flat bar
1 flexible hose
1 3" coupling adaptor for air box
1 length of rubber trim/ edging
6 hose clamps

Tools used

screw driver
100mm hole saw ( if you can find a 90mm hole saw this would be better but i already had the 100mm)
75mm hole saw
drill
drop saw
friend with a tig welder
nutsert gun
angle grinder

If you can't tig weld i'd suggest just using self tappers to get the flat bar on to the long section. I can't tig weld and dont have AL mig wire so i got a mate to do the tig welding for me

if you dont have a nutsert gun, again just use self tappers to the A pillar or rivets

I picked up the 3" tube for a 6 pack of beer
had the nutserts and screws at home
had the flat bar at home

the rubber elbows and snorkel head cost me $125 at a truck bits shop.
the flexible hose was $20 and the adaptor was like $8 or $10

Anyway the hole thing will cost me around $155


just going to put up pics of it fully assembled as it's pretty self explanitory, on and only half way through with it.

Tube lengths so far, this is approximates as you can be a bit off and it dosnt really matter

18" for long bit (along the A pillar)
13" for horizontal bit
4.5" for the vertical bit (attaching to snorkel head)

I suggest you assemble the snorkel first then put it up to the guard to decided where to drill.

you have to drill through 3 sheet metal layers. First one is super easy as it's flat. Second layer is a nightmare. i suggest drilling all the way through with a pilot drill so you can locate the hole saw for all 3 layers.

once all the holes are drilled, go over with paint so they dont rust.

and fit the edging on the outermost hole.

good luck with the drilling. I had to do some cutting with the angle grinder as the second layer was too much for the hole saw.

http://i100.photobucket.com/albums/m.../snorkel45.jpg
http://i100.photobucket.com/albums/m...s/snorkel4.jpg
http://i100.photobucket.com/albums/m.../snorkel46.jpg
http://i100.photobucket.com/albums/m.../snorkel43.jpg



i'll tackle the inside to the air box soon as i can be stuffed.



view from further away

http://i100.photobucket.com/albums/m...20pics/xj3.jpg

give it a go it's really not that hard and much cheaper than getting an airflow or safari one.

Nice job!!

that looks really good and a great write up top stuff!

Thats just what I've been thinking about this week!! Looks good!

I've been patiently waiting for this thread. Good job, looks the part.

Shit hot mate !!
I really like it !! :p

Looks good - what about painting the tube black so it's all one colour?