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I wanted to get MORE cold air through the BYS Intake Plate, so I made a homemade CAI. I spent very little money on it, so my attitude is, while it might not be as high-tech or engineered as some, it still works. It is very stealth. I was able to install it without removing the bumper, and I don't know if I mentioned it yet, it was cheap.
These are the parts I used:
From www.pitstopusa.com
ALLSTAR OFFSET SINGLE BRAKE DUCT -BLACK - 5" X 9-3/4"
3" DUCT HOSE (They only sell the hose in long lengths, so you may find something somewhere else (maybe Home Depot) that you can substitute cheaper. You only need about 10 inches of the stuff.
From Home Depot, in the shelving aisle. The side pieces come in one bag with screws, the bottom piece comes in one bag with screws. You get I think 5 of each, but they don't sell them separately. While your in Home Depot you may as well find some nuts for the included screws. I used what I had around the house.
Here's where I have a little advantage, I have the BYS Intake Plate so I already had my airguide out from in front of the radiator. This is easily removed and there are several threads on the subject (search). You definitely need to take it out though, because you'll need to feed the duct in through the opening.
Take your duct ease it through the opening. Since the duct is flexible I was able to insert it on the right side and when it reached the bottom I moved it to where I wanted it to be. The outlet end of the duct should be on top so the air flows upward. Align the duct and mark your mounting holes on it with a pencil using the brackets as templates. The bottom of the surrounding area of the duct should be square with the last tier of the grill. You'll why see later. The side brackets don't have to be exact as there is some give in the grill. Remove the duct the same way you put it in and install the brackets.
The arrangement should be something like the photo of the brackets on the ground above. Since the brackets only come in silver, you may want to take a can of spray paint and give them a coat. I did this but I was rushing a bit and didn't give it enough time to dry, so mine needs to be retouched.
Ease the duct with the mounting brackets back in the same way. It might be a little harder this time but it can be done. Be VERY CAREFUL as to not damage the A/C piping.
Now your thinking to yourself. How the HELL am I going to screw these things in. Here was the solution I came up with.
The bit is from the screwdriver in my Craftsman set. Its magnetic so it should be able to hold the screw somewhat. Line it up with the holes, and use the pliers to grip the bit to screw down the brackets. I used one screw and nut on each side. Loosen the small self-tapping screw in the OEM grill nearest to the vertical support. If your holes are right you should be able to slide the bottom bracket between the two pieces of the last horizontal grill slat. Again the grill has some give so be patient and bend it a bit if your having problems. Retighten this screw. Make sure everything is as tight as it can be. If you are anal feel free to put a screw through the bottom bracket. I did not and I don't have any problems. I've taken the car upwards of 120 MPH with it this way.
It should end up looking like this...
You may or may not want to use a Dremel with a cutting or grinding bit to cut off the pointy end of the screws when your done.
Attach the hose and route to the airbox. My pictures obviously don't reflect this because I have the BYS plate, but use your imagination.
You can see its VERY stealth on my car with the BYS plate. Yours it should only be noticeable when you open the hood. You will have to use your own skills to route and secure the hose on your application. If your adventurous cut your airguide and route the hose through it. You may want to flare your hose at the end or something its up to you.
Viola. My first S2000 fabrication. I like it seems to cure the bogging and it definitely keeps the airbox cold.
