Calloway CAI Install
Race Director
Joined: Jan 2005
Posts: 10,924
Likes: 854
From: Daytona Beach FL
Getting the shroud out is a real royal PITA!
That being said, the whole install took me about 4 hours. Here's an old thread from when I did it about a year-and-a-half ago. For some reason the pictures are missing in the first post, but the second post has some pictures of the last part of the installation.
Click here to go to old thread about Callaway Honker Install
Good luck!!
Bob
Team Owner
Joined: Oct 2004
Posts: 27,420
Likes: 64
From: San Clemente CA
THEY LIE!!!
Getting the shroud out is a real royal PITA!
That being said, the whole install took me about 4 hours. Here's an old thread from when I did it about a year-and-a-half ago. For some reason the pictures are missing in the first post, but the second post has some pictures of the last part of the installation.
Click here to go to old thread about Callaway Honker Install
Good luck!!
Bob
Getting the shroud out is a real royal PITA!
That being said, the whole install took me about 4 hours. Here's an old thread from when I did it about a year-and-a-half ago. For some reason the pictures are missing in the first post, but the second post has some pictures of the last part of the installation.
Click here to go to old thread about Callaway Honker Install
Good luck!!
Bob
Burning Brakes
Joined: Feb 2005
Posts: 1,099
Likes: 1
From: Branford Connecticut
We believe that getting the access to cooler "outside" air is worth the extra effort.
Thanks for considering the Honker for your car.
Drifting
Joined: Feb 2005
Posts: 1,321
Likes: 0
From: Catonsville MD
Took me about 20 minutes to remove all the fasteners and the shroud. I actually trimmed a little off the bottom passenger side of the shroud that you cannot see when installed and this made it easy to pop it out. It kept getting hung up on me.
Total took me I guess an hour -hour and a half to install the intake.
Total took me I guess an hour -hour and a half to install the intake.
Team Owner
Joined: Aug 2003
Posts: 38,314
Likes: 35
I don't know who you might have talked to here at Callaway, but for most people the removal of the factory radiator shroud is somewhere between "not too bad" and a "pita". It's actually the most difficult part of the installation in that there are several fasteners that hold the shroud in place and, once it's unbolted, it requires some manipulation to get it out of the car.
We believe that getting the access to cooler "outside" air is worth the extra effort.
Thanks for considering the Honker for your car.
We believe that getting the access to cooler "outside" air is worth the extra effort.
Thanks for considering the Honker for your car.
Advanced
Joined: Jul 2004
Posts: 93
Likes: 0
From: Cinnaminson New Jersey
Honker
Wear mechanics gloves so you don't rip up your hands and don't forget you can't hurt the shroud. It bends and it won't break. Like the other forum members stated, well worth the time spent. A definite seat of the pants feel especially when it cool to cold outside
Tech Contributor
Joined: Jul 2002
Posts: 14,950
Likes: 266
From: St. Louis, MO
St. Jude Donor '08
I found the shroud to be a piece of cake to cut with a blade knife when I installed my Vararam. It cuts like butter with a new blade. Just don't stick the entire blade out when cutting the top so you don't pierce your evaporator. Took me 10 minutes or so to do the install IIRC.
That said I don't know if you can cut it in place for the Callaway, but if you can, I think that's a lot easier.
That said I don't know if you can cut it in place for the Callaway, but if you can, I think that's a lot easier.
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Thread Starter
Safety Car
Joined: Nov 2006
Posts: 3,860
Likes: 5
From: Tampa FL
Thanks for the input. Seems to me that unless you pull air from somewhere other than the engine compartment that your wasting your time with some of these cold air kits. Cutting the shroud looks like the way to go.
Instructor
Joined: Oct 2006
Posts: 221
Likes: 0
From: Rowlett Texas
Burning Brakes
Joined: Feb 2005
Posts: 1,099
Likes: 1
From: Branford Connecticut
C6 Honker Instructions:
Non-Z06 -
http://www.callawaycars.com/callaway...structions.htm
Z06 -
http://www.callawaycars.com/callaway...ystemC6Z06.htm
Non-Z06 -
http://www.callawaycars.com/callaway...structions.htm
Z06 -
http://www.callawaycars.com/callaway...ystemC6Z06.htm
Team Owner
Joined: Aug 2003
Posts: 38,314
Likes: 35
I found the shroud to be a piece of cake to cut with a blade knife when I installed my Vararam. It cuts like butter with a new blade. Just don't stick the entire blade out when cutting the top so you don't pierce your evaporator. Took me 10 minutes or so to do the install IIRC.
That said I don't know if you can cut it in place for the Callaway, but if you can, I think that's a lot easier.
That said I don't know if you can cut it in place for the Callaway, but if you can, I think that's a lot easier.
The thread by Beezeye is an excellent thread for the install. I used it and the instructions from Callaway. And definitely wear mechanics gloves while you are working. Its the only way I'll work on my cars.
I 'll be ordering the LGs headers this week and installing them so I'll definitely be following my own advice.
Last edited by '06 Quicksilver Z06; Dec 18, 2006 at 10:24 PM.
Melting Slicks
Joined: Mar 2006
Posts: 2,064
Likes: 4
Dont be too worried. Your not going to hurt anything on the removal.
The Z51 is a little tougher than the base model, only because of the extra coolant lines (transmission and oil cooler)
Take your time and invite a buddy over to help.
Make sure all fasteners and fascia bolts are removed. If in doubt, remove it; then remove some more.
Flex the nose spoiler out and away to remove the shroud.
Oh, order a new factory shroud and store it with yoru OEM air intake.
That way, when you sell the car, you can put it back to stock and sell your Calloway with a pre cut shroud and get most of your money back.
The Z51 is a little tougher than the base model, only because of the extra coolant lines (transmission and oil cooler)
Take your time and invite a buddy over to help.
Make sure all fasteners and fascia bolts are removed. If in doubt, remove it; then remove some more.
Flex the nose spoiler out and away to remove the shroud.
Oh, order a new factory shroud and store it with yoru OEM air intake.
That way, when you sell the car, you can put it back to stock and sell your Calloway with a pre cut shroud and get most of your money back.
Melting Slicks
Joined: Mar 2006
Posts: 2,064
Likes: 4
You could indeed cut it in place, but the Callaway requires the install of rivets and the airfilter frame. For this the shroud will have to be removed.
The thread by Beezeye is an excellent thread for the install. I used it and the instructions from Callaway. And definitely wear mechanics gloves while you are working. Its the only way I'll work on my cars.
I 'll be ordering the LGs headers this week and installing them so I'll definitely be following my own advice.
The thread by Beezeye is an excellent thread for the install. I used it and the instructions from Callaway. And definitely wear mechanics gloves while you are working. Its the only way I'll work on my cars.
I 'll be ordering the LGs headers this week and installing them so I'll definitely be following my own advice.
No offesne bro; DONT cut the shroud in place. Remove it and cut per instructions. Use a good gasket sealant for the frame. This will be very important to the performance of your CAI.
Melting Slicks
Joined: Mar 2006
Posts: 2,064
Likes: 4
You could indeed cut it in place, but the Callaway requires the install of rivets and the airfilter frame. For this the shroud will have to be removed.
The thread by Beezeye is an excellent thread for the install. I used it and the instructions from Callaway. And definitely wear mechanics gloves while you are working. Its the only way I'll work on my cars.
I 'll be ordering the LGs headers this week and installing them so I'll definitely be following my own advice.
The thread by Beezeye is an excellent thread for the install. I used it and the instructions from Callaway. And definitely wear mechanics gloves while you are working. Its the only way I'll work on my cars.
I 'll be ordering the LGs headers this week and installing them so I'll definitely be following my own advice.
No offesne bro; DONT cut the shroud in place. Remove it and cut per instructions. Use a good gasket sealant for the frame. This will be very important to the performance of your CAI.
Melting Slicks
Joined: Mar 2006
Posts: 2,064
Likes: 4
You could indeed cut it in place, but the Callaway requires the install of rivets and the airfilter frame. For this the shroud will have to be removed.
The thread by Beezeye is an excellent thread for the install. I used it and the instructions from Callaway. And definitely wear mechanics gloves while you are working. Its the only way I'll work on my cars.
I 'll be ordering the LGs headers this week and installing them so I'll definitely be following my own advice.
The thread by Beezeye is an excellent thread for the install. I used it and the instructions from Callaway. And definitely wear mechanics gloves while you are working. Its the only way I'll work on my cars.
I 'll be ordering the LGs headers this week and installing them so I'll definitely be following my own advice.
No offesne bro; DONT cut the shroud in place. Remove it and cut per instructions. Use a good gasket sealant for the frame. This will be very important to the performance of your CAI.
Team Owner
Joined: Aug 2003
Posts: 38,314
Likes: 35
My point was that indeed you can cut a radiator shroud in place but it would do you no good since you have to install the rivets and the air filter frame anyway. You are going to want to take it out to cut it. Less chance of error and easier to work with out of the car.
Plus you could damage the AC condensor attempting to do it.
So yes, one can cut a radiator shroud in place (and risk screwing it up, or the condensor, or cutting your hand) but it would be pointless to do so if you are attempting to install the Honker since you are going to have to remove it to install the rivets and fit the frame in it anyway. You may as well go ahead and remove it first and cut it. Do it the right way.
Now if you were trying to install a Vararam, well people have done that without removing the shroud.
Last edited by '06 Quicksilver Z06; Dec 18, 2006 at 11:50 PM.
Le Mans Master
Joined: Aug 2004
Posts: 5,259
Likes: 16
From: Monroe Township New Jersey
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15-'16
St. Jude donor in memory of jpee '14
I don't know what all the fuss is about you can cut the fan shroud correctly in place for both the Honker and Vararam. We installed the Honker in my car and the Vararam in Joeys car. Just remove the four bolts holding the radiator support and place a piece of 1/4 inch plywood between the condenser and the fan shroud as you cut the shroud. I am dangerous with tools when it is cold so anyone can do it.
Cheated with the honker, We screwed it in place with sheet metal screws and a screw gun
then placed silicone seal around the entire outer edge. The vararam will have to be cut a bit lower than the template.
Now we can compare the results once I get the hang of scanning with HP tuners BTW.... It takes no time at all unless you do it with your son while watching Sunday football
Cheated with the honker, We screwed it in place with sheet metal screws and a screw gun
then placed silicone seal around the entire outer edge. The vararam will have to be cut a bit lower than the template. Now we can compare the results once I get the hang of scanning with HP tuners BTW.... It takes no time at all unless you do it with your son while watching Sunday football
Pro
Joined: Sep 2005
Posts: 595
Likes: 38
From: San Jose CA.
THEY LIE!!!
Getting the shroud out is a real royal PITA!
That being said, the whole install took me about 4 hours. Here's an old thread from when I did it about a year-and-a-half ago. For some reason the pictures are missing in the first post, but the second post has some pictures of the last part of the installation.
Click here to go to old thread about Callaway Honker Install
Good luck!!
Bob
Getting the shroud out is a real royal PITA!
That being said, the whole install took me about 4 hours. Here's an old thread from when I did it about a year-and-a-half ago. For some reason the pictures are missing in the first post, but the second post has some pictures of the last part of the installation.
Click here to go to old thread about Callaway Honker Install
Good luck!!
Bob
Tech Contributor
Joined: Jul 2002
Posts: 14,950
Likes: 266
From: St. Louis, MO
St. Jude Donor '08
Wait until you watch your IAT's drop like a rock and your fueling go lean as you reach 100 mph or so (on the track of course). I was surprised to see the actual effects of the Vararam on my car on the HP Tuners logs. My buddy who's an experienced tuner told me that while good tuners richen up the PE table for the Vararam compared to optimum fueling on the dyno, in his experience you can often use a bit more fuel on the track at the upper rpms. It worked for me! .2 and 2 mph from logging and tweaking in the same night.