Alright guys... Time to update. 100 series snorkel install, GO!
So, first step: When you receive the snorkel you ordered, DO NOT throw away the template that comes with it. Now that we have moved past that, Lets get to pictures and what not...
So here is my ghetto template I made and my brand new fender all ready to hack up. My inner fender liner was removed and not reinstalled after all the body work. I measured the distance back from the "S" tube that runs under the fender to decide where I needed my hole front to back. After measuring back from the air box opening, this is where I decided it needed to go. I originally had the template a little higher in the front but decided it needed to be lower on the fender. (WRONG!) At this point I removed the airbox to aid on the install. After marking the mounting holes and the center of the intake hole, I grabbed my drill, took a deep breath, and another, and another, had my brother make fun of me and whip out his phone to film everything... And I cut the hole.
So after all this is done, I realize I put the hole about an inch and a half low. The curve in the snorkel did not line up well with the curve in the fender and it just looked like crap. So, by this point I decide my fender is ruined, I grab the pneumatic nips and oblong the hole up an inch or so. I knew I had just over an inch to play with on the bottom edge of the snorkel. So it worked out ok. You can't see my mess up as it is behind the snorkel but I felt like throwing up for a little while!
I placed the template back on the fender to mark the new locations for the mounting holes, drilled those out, and set the snorkel in place. It lined up much better this time but there was still a little work to do. The snorkel sat on the roll of the fender but was at the very bottom of the curve. The top of the snorkel was angled out away from the windshield and did not look good. I decided to tackle that at a later point and started installing the rubber pipe under the fender. The airbox end of the pipe was a little long so I cut a small section out, maybe half an inch or so. I also cut the end of the airbox off a little to help. I put a small amount of black silicone on the inside of the rubber tube, slid the hose clamps in place and installed the rubber pipe on the external side.
This is a view from the wheel opening of pipe attached to the outer snorkel. That went pretty easy. The other end was a bit more of a challenge. I reinstalled the airbox and, after putting the rubber pipe over the airbox intake and tightening the hose clamp, the rubber pipe kept wanting to slip off. I'm sure it would have been fine if I had not put the silicone on it but being it was a cheap knock-off, I wanted the silicone as added assurance. I looked a round a bit and came up with this plan:
I ran self tapping screws from every angle I could hit, retightened the hose clamp and it held like a dream. At this point I finished reinstalling the airbox bolts, installed my new K&N filter, and reassembled the rest of the intake.
At this point I refocused on making the snorkel look better; like it was intended to be on the vehicle, not like the hodge-podge hack job it actually was. I grabbed a ratchet strap, wrapped it around the top of the intake pipe, ran it across the vehicle, wrapped it around the opposite side mirror, and tightened. When I got it about where I wanted I broke out the heat gun and slowly started heating the entire snorkel. Once it was warm enough, I tightened the ratchet strap one or two more clicks to allow it spring back. At the same time I continued tightening the body of the snorkel to the fender. I over tightened one bolt on the front lower corner. It started to dimple a little so I backed off and quit applying heat. After the snorkel cooled I removed the ratchet strap, fabbed a bracket and called it complete. For how the whole project started, I am very pleased with how it turned out. You can still see a little dimpling on the front corner but ottherwise I'm pretty happy.
So, there you have it. A 100 series snorkel installed the wrong way but made to work!