Hughes Magnum Air-Gap Install

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805moparkid

805moparkid

Slant and AFX Guy
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hey guys i havn't seen any of you post anything on it so i figured since i have one in hand i would post how the install goes!

First thing i noticed out of the box is how nice the casting is, there were no burr's or "uglies" that i had or even wanted to touch up. Started looking over the parts and looks to be a very complete kit, needed gaskets, TB adapter, etc. Looked down the mating surfaces and they all looked fine except the adapter to intake flange. After kissing it on the belt sander it was not flat BUT not out by much, but probably enough to leak.

I also tapped both bosses, one for water temp and one for manifold vacuum, for later use. So after the prep i got it cleaned up and painted my usual cast iron.

will post more as i move thru the install and after results, for a bench mark after i did all the work to the kegger ( http://www.forabodiesonly.com/mopar/showthread.php?t=233963 ) and before the gasket went again i had a best of 14.2mpg on my trip from phx to LA on I-10 (75mph).
 

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Abodybomber said:
Subscribed.....
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this thing is great, Nice port dual plane should make great tq without the issues of the kegger.

its starting to rain and really windy so im stuck probably for tonite... bummer as i wanted it mounted up tonite!
 
nothing outta the norm of any other intake install. I had mine on the engine before I installed the engine so that made it way eaiser. with that intake it makes it way easy to get to the dizzy once it is in the truck
 
spikekid999 said:
nothing outta the norm of any other intake install. I had mine on the engine before I installed the engine so that made it way eaiser. with that intake it makes it way easy to get to the dizzy once it is in the truck
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yea i bet! i did a ignition R&R when i first got it and boy that was hard to get back in there!

Little update i got as far tonite as pulling the kegger. tomorrow should be fun!
 
805moparkid said:
yea i bet! i did a ignition R&R when i first got it and boy that was hard to get back in there!

Little update i got as far tonite as pulling the kegger. tomorrow should be fun!
Click to expand...

yup, found that out on my truck when I got it too lol
after I got the engine in it wouldn't start, turned out the dizzy was 180, I was actually able to get back there to remove it lol
 
spikekid999 said:
yup, found that out on my truck when I got it too lol
after I got the engine in it wouldn't start, turned out the dizzy was 180, I was actually able to get back there to remove it lol
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yea they were not thinkin on that one...
 
not at all

I dunno if your running a open air element or not, but I just remembered it does sit up a lil higher, so if you got a paper filter it may be a ***** to get it in place. I have a k&n filter so it flexes enough I can get it in there
 
spikekid999 said:
not at all

I dunno if your running a open air element or not, but I just remembered it does sit up a lil higher, so if you got a paper filter it may be a ***** to get it in place. I have a k&n filter so it flexes enough I can get it in there
Click to expand...

im running the stock system for now, as its a B.O.V im thinking a snorkle and has to be able to get in deep!
 
im gonna end up putting it into the bottom of my air cleaner, but i have to extend the wires. at the moment i just have it sitting there
 
We did one earlier this year, worked out great. This 408 is getting 19-22mpg (city/HWY) and is making around 450HP, or almost 2X that of a stock 318 that it replaced, and it was getting 13-16mpg.
 

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MRL Performance said:
We did one earlier this year, worked out great. This 408 is getting 19-22mpg (city/HWY) and is making around 450HP, or almost 2X that of a stock 318 that it replaced, and it was getting 13-16mpg.
Click to expand...

wow thats awesome and i want to do a 426" kit someday! those are numbers i would be perfectly happy with, what heads, compression and cam did you run?
 
what an F'ing day... i just sat down after FINALLY finishing this thing up...

ok so i'll start from the beginning, started at about 9am this morning, got the old intake off, surfaces cleaned and ready for the new intake. After that it started going down hill...

The directions Hughes supplied are very good and clear, BUT are for a different style of fuel rail (thats when i knew i was in for it...). in all the pics they have what looks to be steel fuel rails with flat steel supports, well my 97 has plastic rails and plastic supports. As you can see the "Z" supports that Hughes supplies work just fine other than having to trim the bracket for what i recall being the purge solenoid.

Now where the fun begins, they supply the "C" spacers to use on opposite corners again for the fuel rails, but again for the other style rail. In the pics you can see they are way off, the first one i just cut the outside lip off the bracket and it worked out ok, if i would have just installed it, it could have cracked the rail and would have angled the injector so bad the Oring may not have sealed or the spray would have been right onto the injector passage instead of into the air charge.

For the next post notice the two fittings at the back of each rail with a black nipple on them.
 

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ok so after refabricating their mounts i was going to install the supplies hose to connect the two rails...not so fast...

after my only choice was to cut the original hose off as it wasn't going to work due to the change in angles (per instructions) i went to install the new hose. As you can see the hose diameter's are WAY different... the original is just shy of 3/8" and the new midget hose is maybe 1/4", both being hard plastic and not forgiving...

So i have some 3/8" EFI hose on the parts list.

So now i have the intake ready to bolt on, i re wipe down all the surfaces, install the end seals and goop the corners, install the intake gaskets, set the intake down and guess what! Due to the huge square boss for the injector pairs its sitting on top of the valve covers... Well by this time the sun it peaking over the house and the sealer is going to go fast. So i yanked the passenger side V/C off and notch around those bosses. after pulling the covers the intake sank to its final resting place and it was good and flat :blob:

After snuggin down the intake i hooked everything back up, tried to install the new end on the cruise control but the cable is now to short...

The next thing i had to do was relocate the IAT which i knew i was going to have to do. not really wanting to get into extending wires and making thing hard on myself i chose to put it right in the filter box. start to drill the hole and bam, bottom of the filter box cracked and shattered a hole... tried another hole with better luck.
 

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So now the truck is back together, ready to sit and let everything cure overnite. When ahead and installed the pulley on the crank which was the easiest thing i had done all day since getting out of bed, nope... it was easier than that to...

So here is where i am at with this thing.

The intake/adapter as great peices, clean castings, everything is where it needs to be, +1

Hughes obviously didn't do their homework on the different years of magnums because if they did they would have had a correct install kit for these FACTORY rails. The supports are wrong and the fuel line is wrong which if you are not planning on and have a set time REALLY screw you. -1

Next is the gaskets they sent... They didn't send expected Edelbrock or even hughes permaseal gaskets, they sent super thin Victor R gaskets... i just spent 600 bucks + shipping and your going to give me these **** gaskets? Thanks -1 :finga:

Overall im every excited about the part, but just like when i bought my victor heads HUGHES themselves dropped the ball. I will be contacting them so they can get this fixed for future buyers with less time and fab skills.

I would really care but this thing is advertized as a drop in, EZ deal...

Will post when its up and running and new MPG readings
 

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Quick Update!

after 3 heat cycles the check engine light came back on for a misfire #7/ Coil Dwell problem. So i replaced the crappy stock wires and coil for a DUI Live Wires and DUI 45K coil while opening up the plug gap on the NGK's to .065 (per their spec). Reset the computer and after 50 miles and a couple of heat cycles its staying off!

Now back to the hughes. No leaks! on the first 200miles it went from 10mpg to 13mpg (but before the coil and wires) so i suspect after the computer does more learning and get more miles on it it should be up in the 14's or higher. Not great but better than it was!

will update again later
 
I have never seen those plastic fuel rails before.
every second gen ram ive seen have had the steel lines, including mine
 
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