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  #16  
Old 08-04-2014, 12:36 AM
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Continued..

I fabbed up two walls of duct. These are not pretty, but will be functional.
To respond again about making templates, I basically made these pieces very complicated. I can't convey the angles and bends into a template. I know I'll be doing this retrofit again on another car, so I think a fiberglass solution will be next to possibly make it easier.

In the meantime here is the sheet metal version.


On the driver's side, the shape is unorthodox because of the need to accommodate both the cowling drain and maintaining the space volume under the filter for air flow. I resorted to a sheet of aluminum to get the angles and bends.
Not pretty at first.. But it got me to this basic shape.


Then I bent it to this form. Still not pretty, but looks better than the aluminum mockup.


Dry fitted to it's location.


.
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Last edited by DeliveryValve; 08-04-2014 at 12:46 AM.
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  #17  
Old 08-04-2014, 12:36 AM
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Passenger side was not as intricate and I was able to make a template from cardboard. Still needed to design and make the bends to clear the windshield wiper motor for this template.


Which then I transferred the on sheet metal and bent it to shape.


Test fitted..


Next will be the installation of the pieces and making a filter door.
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  #18  
Old 09-04-2014, 12:58 AM
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Following with great interest!
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  #19  
Old 09-04-2014, 01:34 AM
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Looking good man!

Scarier than breathing all that junk, and cutting holes in a Benz is you holding a camera with one hand, and actively cutting with an angle grinder in the other!
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  #20  
Old 05-12-2015, 04:45 PM
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Quote:
Originally Posted by WVOPWRD! View Post
Looking good man!

Scarier than breathing all that junk, and cutting holes in a Benz is you holding a camera with one hand, and actively cutting with an angle grinder in the other!
Yep, not good for safety!
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  #21  
Old 05-12-2015, 04:45 PM
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After a long hiatus, I am finally making an update to this thread.

I left off at the fabrication of the duct and the next step I did was the fabrication of the filter firewall cover.

With the filter sticking out a bit from the housing, I had to create a recess in the cover.




The final look of the cover installed on the firewall. If you noticed, I also began to cut a new hole for the wiper motor plug.



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  #22  
Old 05-12-2015, 04:46 PM
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Unfortunately, I lost some of the pictures of the installation since I did this awhile back. I ended up painting the pieces and using Automotive Windshield Urethane Adhesive to glue everything together. A bit of a mess to do and I didn’t quite get the Urethane all smooth.




With the new duct now in the way, I had to cut down and glue together the now smaller left cowl gutter or drain (shown on the top).



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Last edited by DeliveryValve; 05-12-2015 at 07:14 PM.
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  #23  
Old 05-12-2015, 04:47 PM
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Overall I am happy with the installation. The ease of changing out the
filter and I am satisfied in the way it looks on the firewall.






Like majority of other vehicles with a factory designed cabin filter, you can feel a noticeable air flow restriction. My original test filter was destroyed by mockups and the installation process. It was a basic filter and I wasnít able to test it in the working system.

So I ended up using a Fram CF10370 carbon cabin filter as my thinking would be it will do a better job of cleaning and freshen the outside air. But after I purchased it, and then reading the reviews, it has been said this type of filter restricts the air more than a standard filter.
In the mean time Iíll just run this filter until it is time to change and then find a more free flowing unit.

As far as other folks doing this mod, perhaps an even larger filter than the 8x7 inch filter could be some how crammed in there to provide a much better flow of air.

One other side note, I also have since did an additional modification regarding the recirculation aspect of the cabin air. I did this mainly to prevent smelly air from coming into the cabin. Here is the link.
w123 HVAC recirculation modification



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  #24  
Old 12-26-2016, 10:27 PM
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How has this been working out?
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  #25  
Old 07-12-2018, 09:42 AM
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Question Cabin Air Filter

Three years later, did this work out O.K. or what ? .
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  #26  
Old 07-14-2018, 02:32 AM
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Quote:
Originally Posted by Shawnb View Post
How has this been working out?
Sorry it took so long to answer. Just never came back to this thread....

Quote:
Originally Posted by vwnate1 View Post
Three years later, did this work out O.K. or what ? .
I am definitely glad I installed this filter. I opened up the cowling earlier in the year when I had wiper motor issues during the rain. I wished now I took pictures, but that cowling was full of dust, dirt, twigs and little seeds. I just can't imagine not having a filter there to keep that stuff from getting stuck in the evaporator and not to mention breathing it all in.


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