and also, did you have to relocate the battery?

I don't have any sort of dremel or whatever... All I have are some aluminum/sheetmetal cutting scissors and I still can't work them around that little space to cut out the whole for my PR CAI to go through. Is there any other way I can hack this?

I used a dremel...and I trimmed the battery tray..I later learned about redrilling the mounting holes for the tray.and just moving it toward the passenger side a little...

Dremel man, can't use the battery ones either, you'll jsut waste your time, gotta go with the cord heavy duty ones, I went through like 10 cutting plates to enlarge the hole.. it was a real b!tch!

Anyway, what I recommend you to do next is to get a rubber hose you're not using, and cut it along the side and use it as a molding strip to protect against scratches and stuff.

I rented an 18 volt drill from Home Depot and just drilled about 30 holes making a circle. Then I punched out the center.
and............BAM..............new hole for CAI.
Hell, yeah I relocated the battery!!!
Why not!!

You guys are making way too much work for yourselves. Do what I did - lay underneath your car, get some really strong pliers and pry the metal back where the small air horn hole already is. I've done this on 4 SR20's and it worked fine. Hole won't be perfect but it takes less than 10 minutes to get the hole big enough.

Or lose your patience like me and rip a hole w/ pliers! Looks like crap, but it worked. :) If I could do it again, I'd take a little more time with it.
Jason

Originally posted by SmoothDaddyFig
I rented an 18 volt drill from Home Depot and just drilled about 30 holes making a circle. Then I punched out the center.
and............BAM..............new hole for CAI.
Hell, yeah I relocated the battery!!!
Why not!!

YEP! That is the way to do it. http://digilander.iol.it/Accnasio/smileys/ehm.gif .

At least with the AEM CAI, it has the tools to relocate the battery. Very easy to do!

Look, do it right. Get a drill and either enlargen the holes that hold down the battery or get a file and "slot" the holes.

As for the hole for the Cai, get a jigsaw to enlargen the hole or get some cutting pliers and open it then deburr the ends with grinding stones. Be paitent and do it right cause that hole is permemant.

I bought a recipricating saw from sears.. then i made the hole and returned the saw...

although, i did cut the whole a little bigger than what i should have but it works.

I just need to relocate my battery to the trunk. anyone in garden grove, CA or withing a 50 miles radius wanna help me out. im willing to drive hehe..

I used a sawzal and a dremel for the ends, i wouldnt recommend doing it like this but hey it worked.
Sean

Dremel, sparks are fun.:D

I bought a 3" drill bit, used it once, let someone borrow it, have not seen it since then :) those bits are expensive though, and I had to cut twice with it, and made it really unfun

Originally posted by Storm88000
You guys are making way too much work for yourselves. Do what I did - lay underneath your car, get some really strong pliers and pry the metal back where the small air horn hole already is. I've done this on 4 SR20's and it worked fine. Hole won't be perfect but it takes less than 10 minutes to get the hole big enough.

do this.. i did it and it works fine (unless ur super pickky about the engine bay look). just use those metal cutters to cut slots and peel it apart from the bottom like an orange..

so nobody else used shape charges? hmmm............

i used an electric dremel tool and bought a "carbide" bit for marbles,wood and metal. it works good. only took me 2 minutes to cut the hole i need for my cai.

just drilled about 30 holes making a circle. Then I punched out the center. (SmoothDaddy)

This is how I did mine and then file down the edges! I tried to use the circular saw but it just kept jumping all over the freaking panel!

I trimmed the battery tray (Black200SXSER)

And did this as well. I didn't know about moving the tray, guess now I know! :D

It is a bit snug! You'll have to adjust everything on the CAI to make it fit. I use a windshield sticky to use around the hole to prevent scratching the CAI.

I used I high speed grinder. It is small enough to fit in the tight areas inunder the fender. The high speed grinder is a must for anyone doing sheet metal work.
Cuts sheet metal perfect with little effort.