Noise Generator Delete Plug Dimensions
 

This is intended for those who want to make their own plugs for the noise generator delete. If you're just looking directions on how to remove the noise generator there is a far better DIY for that here:

http://www.ft86club.com/forums/showthread.php?t=7975

Edit:
I appreciate the interest but I don't have any extras, or the desire to start making or selling plug sets at this time. I suggest contacting some of the forum's vendors to let them know you're interested. I'm sure if there are enough buyers there will be someone who has the right resources to make at least a limited production run.

If someone wants to copy my design and sell it feel free I'd be flattered.


-All measurements are in inches

-I'm lucky enough to have access to a machine shop with a lathe, but I'm sure there are other ways plugs could be fabricated. Be creative!

-I used Delrin because it's easy to machine and excellent for applications like this (plus I had some laying around) but you could substitute with just about any material that's suited for the heat of the engine compartment

-I decided to go with a full delete back to the firewall. This requires one plug at the intake, and one at the firewall.

-Tolerances don't need to be all that precise since the plugs go into rubber fittings, but if built to these dimensions they will fit great.

Let me know what you think, and if you decide to make your own I'd love to see pics.

http://www.ft86club.com/forums/pictu...pictureid=1524

I designed the firewall plug a little longer because it's hard to reach and a little better grip doesn't hurt.

http://www.ft86club.com/forums/pictu...pictureid=1525

http://www.ft86club.com/forums/pictu...pictureid=1526

This was the best picture I could get of where the plug goes into the firewall. It's not visible but once you feel where the noise generator goes it's not hard to find by touch.
http://www.ft86club.com/forums/pictu...pictureid=1527

The Intake Plug

http://www.ft86club.com/forums/pictu...pictureid=1528

http://www.ft86club.com/forums/pictu...pictureid=1529

http://www.ft86club.com/forums/pictu...pictureid=1530

I added this topic as a link inside of the Noise Generator Delete topic:
http://www.ft86club.com/forums/showthread.php?t=7975

Looks really good. Nice alternative to what I did.

I see the diameter of the intake plug is 1.59" on neutron256's drawings. What is the inner diameter of the original hose that goes into the intake outlet hole (the front end hose of the noise generator) ?

Another question is without the clamp tighten how loose or how much space between the noise gen intake hose and the intake outlet to the hose?

I'm not quite understanding what you're asking. Maybe it would help if you explained what you're trying to do.

Are you thinking of making a plug that goes into the intake side of the noise generator while leaving it in place?

>>Are you thinking of making a plug that goes into the intake side of the noise generator while leaving it in place?

Sorry that is wasn't clear, but yes that is what I'm thinking. Thanks!

Okay makes sense. I thought about doing something like this but then decided I wanted the whole thing gone.

The inner diameter is 1.31" (33.27mm). This would be tricky because it has a hard metal insert to support the clamp on the outside of it.

An expanding plug like xcelir8BRZ used for his might work if you can find the right size.

http://www.ft86club.com/forums/showthread.php?t=10800

I would be careful though you don't want anything that could come loose and get sucked further down into the intake.

Let us know what you come up with. It's a great idea if you can find a way to make it work.

Ok thanks for all the info.. If I come up with anything I'll let you know. :) The other trick for me is to find time to work on it. Cheers!

I know the feeling. Never enough time, or money to pursue all the ideas I have rattling around in my head.

i like the firewall plug... let me know if you start to make and sell both of them... I really like that theyre in black

Sorry just not worth it. Someone had approached me about using my design and selling them, but I haven't seen anything since.

The demand for these vs. the cost to produce them just doesn't work out.

Thank you. I'd really like to know if this modification made that much of a difference or not. Was it worth the effort?

For me it made a big difference. It's much quiter inside the cabin especially on the passenger side (or so my wife tells me). The noise generator produces a hollow higher pitch sound then I like (sounds like an exhaust leak to me) and I'm happy it's gone.

Does the modification make any difference to performance/warranty/reliability. I would like a quieter cabin.

None at all.

Those would have been nice if they were mass made. But I just ended up using Lowes parts for cheap. Here is the link of what I used.
http://www.ft86club.com/forums/showt...?t=7975&page=3

How much would you pay for a set? Just asking because if there are enough people willing to pay enough I would do a small production run and sell them. I doubt it would be worth while though.

I would pay around 30-40 for one that looks as clean as yours.

Well I don't need one now because I'm running what I posted. I could always dye the white PVC to black or whatever color I want. Make a new thread and see if there is an interest!

I'll run my design throug an on demand prototyping company and see what I can get the price to.

I might be able to get them SLS 3D printed in ABS for around that price.

Having them machined out of Delrin is probably going to depend on batch size but to get it down to $40 would need to be a batch of at least 100

okok thanks :)

You never posted details of this. What ended up happening?

The cost is way too high unless I get into quantity of hundreds. Sorry I just don't have the time or energy to get into manufacturing enough to make it profitable.

If you can't find a plug and are satisfied by just "capping" it, here's an alternative solution, from Home Depot (in the plumbing/piping) aisle. It's a flexible rubber cap that you tighten around the opening.

I didn't need to cap the part from the intake tube since I got an aftermarket intake.. but I used it to cap the other end of the sound tube (until I find time to remove it completely). I think it comes in 1" and 3/4" size too in case anyone needs those. The one I used (in the picture) is a 2" cap.

http://i965.photobucket.com/albums/a...psb496e6ab.jpg

I plan on removing the whole thing, but that is clever. i think i see some kind of forced inudction ^^

I did it! I went to Home Depot last night and found the $.60 part and installed it in less than a min and OMG! The sound is so much better. Screw this sound tube!

Na it's just FA20club's 4-1 header. Feels like a mini-FI with their E85 tune though. ;)