JK DIY Snorkel write-up

[Whitepuff]

hi guys,
scraped together the guts to do a DIY Snorkel installation on my JK, so here's a little write-up of the nerve racking process - not fun to cut holes in your bonnet!
Friend and myself ordered the snorkels together to save on the shipping (he also has a JK) and we tossed a coin to see who's Jeep will be the guinea pig
My Jeep was done first.....
We received the two kits without instruction and managed to get hold of the AEV instruction manual form the net, which seemed to have good enough info to do the installation (the snorkels we got ended up being exact replicas of the AEV)
The Kit:


Note the nice embossed "WRANGLER JK" on the Snorkel
The bracketing and trim that came with the Snorkels however was only painted satin black finish and we decided to rather wait a couple of day before we install and get them powder coated, which turned out to be a fantastic idea - finished product looked great:
Before:

After:

We used the AEV template from the installation manual as the snorkel didn't come with a template to cut the hood, and the AEV one looked like a good enough fit.
First off we taped off the hood nice and thick with 4 layers of masking tape - didn't want to scratch the hood in the process - nice big area:

We next removed the airfilter, then airbox (couple of clips, 2 bolts and a electrical plug) and removed the stock air intake be unclipping it and clipping the snorkel into it. Used silcon to seal off the snorkel inside the airbox, and all the small holes inside the airbox, and let it dry in the mean time

Next up, installed the snorkel with the hood open - 4 existing bolts 0 two on fender/ side panel in the engine bay and two on the side of the windshield. Clip the box back into place (using silicon spray for easing in the box into the rubber mountings)
Next up we aligned the template and the snorkel and stuck the template on the bonnet using the AEV measurments and soem adjustment to center it over the snorkel:

Then the hair raising part - using center punch punch the marks for the two 50mm holes with hole saw and then using motor oil as lube drilled the 50mm holes with the holesaw on the template, through both layers in the hood (outer surface and hood support)

Then using a jigsaw with a long metal blade (fine tooth) we cut out the rest from the edge to the first hole, then between holes. At the same time cutting through the support layer as well.


Closed the hood, and checked the clearance - should be around 3-5mm around the snorkel. Using a drilling machine adapter we used a thin grinder cutting disk to trim off the excess metal on the inner support of the hood to get proper clearance on the inside - the template ensures the outside of the hood clear's first time, but the inside hood support layer needs additional trimming - also mentioned in the AEV manual

Using some scotch-bright we removed the burrs on both cut edges and used some touch up paint to cover the bare metal surfaces after cutting. next up we closed the hood, and lined up the metal trim, and marked and punched the markings for the holes to fasten the rim to the hood. The kit comes with aluminium pop-rivets but we decided to get stainless allen-cap screws and nylon lock nuts.
After drilling the 4mm holes for the allen caps, we removed the masking tape, and using black silicon we sealed the trim and hood and fastened the caps screws and lock nuts.

Next up was to install the scoop or Ram head - slip on and using the supplied black hose clamp tightened it to the snorkel main body
and the end product:

Took us around 4 hours to do the installation of the first one and 3 hours on the second one due to double checking everything - can always remove somemore metal, but can't put anything back....
As for costs:

• Snorkel kit - R1800
• Hole saw, jig saw blades and allen cap screws - R180
• Powder coating brackets - R180
• Chuffed feeling when you close the hood and all fits perfectly? - Priceless

Took it out for a spin, and first thing I noticed is the fuel consumption jumping up when traveling at slow speeds - suppose the longer suction has an impact, but when moving faster than 60km drops it right down again when the RAM effect comes to play. Initially I was disappointed because of this effect on the fuel consumption as I am used to below 9l/100km figures on the open road and suddenly this jumped up to 15l/100km around town - although I reseted the fuel consumption and then started driving with the snorkel which will have a detrimental impact as it measures average consumption and our little town has a lot of speed bumps - causing stop-go driving the whole time, killing the consumption. But took it onto the highway this morning and it dropped right down again
Overall, it looks fantastic 8)8), and I think it will have a good impact on the quality of the air going into the motor.
Only thing I can't get around in my head is how does rainwater effect the RAM head? Same even on the AEV.

[Die Skim]

You must have balls of steel to do it yourself! Great job!! It looks great!

[EstianSwanepoel]

My AEV snorkel has no effect on fuel consumption.
There should be enough suction to hold a piece of paper.
Ram air is just a bonus at higher speeds.
The AEV and Safari Snorkel ram heads have drain holes for rain.


"Though the Air Ram is no match for the Pre-Filter's ability to remove dirt from incoming air, it has the ability to separate rain from the air charge. It does this by using the force of the incoming air to direct the rain toward small weep ports built into its backside. This design is so effective that drivers will often find their air box is completely dry even after hours of freeway driving in heavy rainfall." - AEV

[Dirk]

I do not like the look of this snorkel, but I also do not like the 110 different pieces of the Safari, guess this one does make more sense, will order the Mopar (AEV) from dealer sooner than later.

[^Strider^]

Great write up Whitepuff, thanks. Snorkel looks great.

[Apocalypse]

Looks great!!

I have one question - you said you get 9l/100km?

A V6 Auto Unlimited?

please tell me the secret!!! I've never got that kind of mileage on my CRD!! I'm happy if I can get it to 12!!!

Dirk wants to know too!!!

[EstianSwanepoel]

Owner of AEV has this to say about the above product.

"Its a cheap copy made in Malaysia with crappy linear plastic.
They pulled a mold off of one of our parts
they tell people to go to our website to get the instructions
they use our photos or photos of our snorkel
They claim its the same for less cost, when in fact it is poor quality and a much lesser grade material that will not hold up in the sunlight and is not nearly as strong.

AEV Snorkels:
Are designed completely in house with our math data going directly to CNC machines to produce the tooling. The knock offs are pulling molds off our parts which have already gone through a shrinkage cycle in the mold process.
Our parts are produced in the USA
Use High density cross linked polyethylene, the strongest type of plastic in the world for such products. The knock offs are Low Density Linear Polyethylene.

The same company normally rips off Safari Snorkel (ARB) but this time I guess they liked our design better

Hopefully most people understand that you get what you pay for, after all considering they had ZERO R&D time or money into the thing, they should be able to sell it a lot cheaper then they are. If you look on Chinese sites, you can find ARB knock offs for $40.00...but they look like they cost $40 when you get them.

Wait till you all see the fiberglass knock off I have at my desk from a company in Puerto Rico. It has our logo and everything in it and is basically a movie prop with tons of Bondo...

dh"

[Dirk]

Some may say it is a waste, but I am going to Mopar/AEV route, R3200 vs R1800, not that much more for the real deal.

[O.B.]

Glad to see you can also drill DIY holes in a Wrangler.

Looking like an even better option...

[Whitepuff]

Looks great!!
I have one question - you said you get 9l/100km?
A V6 Auto Unlimited?
please tell me the secret!!! I've never got that kind of mileage on my CRD!! I'm happy if I can get it to 12!!!
Dirk wants to know too!!!

jip, CRD with autobox and using speed control set on 120km -gps says 117km/h

realize its a knock off, but looks good, and made of 4,5mm plastic all the way through..very sturdy. We just had to powdercoat the brackets as the finish was a bit crappy. but snorkel's finish is great. didn't have double the cash to spend on AEV, so this option had to do.

[HeinrichC]

Drilling holes in a JK, I would be way to nervious!!!

[Jeepiscool]

jip, CRD with autobox and using speed control set on 120km -gps says 117km/h

realize its a knock off, but looks good, and made of 4,5mm plastic all the way through..very sturdy. We just had to powdercoat the brackets as the finish was a bit crappy. but snorkel's finish is great. didn't have double the cash to spend on AEV, so this option had to do.

Down a mine shaft

[Jeepiscool]

Oh yes with the CRD yes. For the 3.6 V6 you'll need the mine shaft, but do remember to kill the ignition.

[Zombicon]

Some may say it is a waste, but I am going to Mopar/AEV route, R3200 vs R1800, not that much more for the real deal.

where did you get R3200?? I phoned 2 Jeep Dealers and got a price of over R4700....?

[EstianSwanepoel]

where did you get R3200?? I phoned 2 Jeep Dealers and got a price of over R4700....?

Whaaaaaaaaaaaaat? That's ridiculous.
I paid well under 4k for mine and my installation at 4x4MW was R300.

[Zombicon]

Whaaaaaaaaaaaaat? That's ridiculous.
I paid well under 4k for mine and my installation at 4x4MW was R300.

SEEE-RIIII-AAAAAAAAS!!!...

You don't want to know what the rest of the stuff worked out on CAI(CWI) R3k+ fuel Flap R1700, CAt Back R9K+.. I think the best price I could get was on custom bumpers F+R for 15k... An i LIKE!!..

[EstianSwanepoel]

SEEE-RIIII-AAAAAAAAS!!!...
You don't want to know what the rest of the stuff worked out on CAI(CWI) R3k+ fuel Flap R1700, CAt Back R9K+.. I think the best price I could get was on custom bumpers F+R for 15k... An i LIKE!!..

Yeah, R15k is the going rate for a set of the Mopar bumpers. It's extra to add the tyre carrier to the rear bumper.
Nearly R2k for a fuel cap? They can go take a long walk on a short pier.

[Zombicon]

Yeah, R15k is the going rate for a set of the Mopar bumpers. It's extra to add the tyre carrier to the rear bumper.
Nearly R2k for a fuel cap? They can go take a long walk on a short pier.

Not mopar...


I really want the snorkel... but.... I just hate how it looks... in general....

[Whitepuff]

where did you get R3200?? I phoned 2 Jeep Dealers and got a price of over R4700....?

Exactly the reason why I decided to go for the R1800 option.....

[Zombicon]

Exactly the reason why I decided to go for the R1800 option.....

Every time I read your username... i want to smoke....

I am still in two minds.... might have to do the normal thing and do something that no one else has done.... CWI....