This was in another thread but I've moved it here in the hope its easy to find for anyone who needs a starting point for this sort of thing.
My custom air system - The final product:
The old Air filter for those that haven't popped it open to see, the 77TSI doesn't use a panel filter... there is a panel filter listed on K&N, but its for the N\A model of polo or 1.4:
Our idea came from the fact that the old filter is a pod shape, held into place against the TOP pipe entrance of the air box facing the bottom of the box (so straight up and down.) It was held with a screw mechanism, so twisting the whole filter to the left popped it off.
We then used some screws to mount a pod filter adapter plate over the part where the old filter screwed on:
The end result meant a pod filter (K&N) could be affixed to the plate and covering the entrance exactly where the old one sat.
First off:
Undo the butterfly clip holding the intake pipe to the airbox and pull the pipe off, I've also marked the PCV pipe, this is very fragile as the part where it connects to the main intake pipe is held with very thin plastic on the inside, handle with caution.
Undo the 6 screws holding the top of the air box down:
Now the rest I don't have pics of but once you've gotten this far and so long as you apply common sense (and if I'm typing this descriptively enough of course) then the remainder should all make sense enough..
Take the top of the airbox off, the old filter is attached to this and will also come out with it - lift it straight up.
While holding the removed piece of airbox, twist the old filter to the left. The entire thing will pop off.
You can now fix the Pod adapter plate over the hole that the old filter covered. From there attach the Pod filter, now we tried various different filters (straight, pod and cone) what we found to fit the odd shape of the box most was the cone filter, it isn't quite as deep as a full pod filter and had the perfect circumference to fit into the bottom half of the airbox (Notice also that there is a cylindrical piece of plastic that come UP from the bottom of the airbox, this stopped us from being able to fit deeper filters.
Those daring enough feel free to cut it. But my goal was to do this without too much destruction of the original setup.
The two products I used:
When buying the adapter be sure to check the circumference of the hole that the old filter covered so that you can match it and not have any leaks. i believe it was a 3" circumference but I could be wrong.
I'm open for suggestions on improvement, but please; constructive criticism only.
If anyone has questions I'm also open to PM and can give out my mobile number too.
You'll probably notice my filter it pure silver... thats because I'm trying out the new stainless steel filter range, it uses a very very tight weave of metal instead of fabric and metal, the advantage is no fabric at all means much much less restriction on airflow and an easy hose out to clean it... some might argue that it wont catch all dirt or might let drops of moisture through, but in my opinion anything getting past the weave on that baby would likely get through fabric weave anyway and as for moisture, it would likely dry out from the airflow and atmosphere in the piping long before it gets anywhere else... unless you jam hose down there
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Originally Posted by jaedencook
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