ok, cool...well, tommorrow im going to take it to an independant muffler shop and find out what pieces are still ok....you think they would de-rust any parts that i decide to keep assuming its salvagable? I'm also going to buy my intake components tommorrow...what are all the parts/supplies im going to need and where can i get them?

I listed the sources and prices for each part in my link to where I did my intake. Just read that:

Auto Zone pipe part # 8219 $42.00 (cut down by 4")

K&N RX-4750 from AJ USA $49.00
http://www.ajusa.com/cgi-bin/knfilte...27e2373051b38a

Silicone 4" - 3" reducer part number PWRR40-300/400 $26.00
http://www.pwr-performance.com/coupler.htm

$117.00 for parts and about 2 hours to install.

You also need some wire to lengthen the Air Intake Temperature sensor. I used the yellow and black wires from a computer power supply extension cable, and spliced them in using crimp connectors, then wrapped them in electrical tape and finally added a length of split-loom tubing to keep it looking factory.

You'll also need to enlargen the hole in the K&N filter for the Air Intake Temperature sensor. Like many others around here, I used a hot soldering iron and just rotated it around for a while until it was the right size. Be sure to trim away any dangly bits. I had to buy a hose clamp too. I used one that came with the rice pipe, and needed one larger one for the silicone coupler, and I got that at Home Despot.

Your exhaust guy shouldn't have to "remove" any rust, if any of your pipes are still good, the surface powdery rust on stainless exhaust is no big deal. If you need pipes you need pipes. If you can't dig up a factory exhaust at a salvage yard, you'll have to go aftermarket with whatever your exhaust guy can provide. -Worse things could happen.

For clarification, Series 1 engines have an IAT harness long enough already, and it doesn't have to be lengthened.

ok, so i don't need the wire to lengthen the AIT wire?

I bought all the pieces for the intake today except the wire extension (if it'* even needed i guess) and the silicone wire. I had one question about the silicon wire. I saw some silicone at autozone, but the stuff bugsi recommended (that he got) was off of PWR performance website. Will the silicone at autozone work or is there a difference?

I also had my car'* exhaust examined today by an independant muffler shop (sort of - Atlas muffler) and they said that the catalytic converter, the main pipe (the big one) underneath, and the muffler needed replaced. I guess that means the pipes coming out of the back of the muffler are still good and the resonator is still good. That'* good news! So, pretty much all I need to replace is the cat converter, the muffler, and the main pipe.
I'm gonna order those parts online tonight (the ones I listed previously), and as far as the main pipe goes, I guess I'm gonna have to settle for an aftermarket one (which sucks).

As for the tips, Im going to go ahead and follow Bugsi'* lead and order those oval ractive tips. Hopefully, in the next two weeks, I can have it all put together. I'll try and get some pictures of the before and after of my intake and exhaust.

If someone could answer the couple of questions I asked, it would be much appeciated. Thanks a lot!

Oh, one more question! For Bugsi - the hose clamp you speak of...what'* it for? and what size is it?

Whether or not you need an IAT extension is dependent on your year and trim level. Please put that in your signature. There are 5000 members here and I can't remember from one minute to the next who drives what.

Get a second opinion on the exhaust. They WANT you to pay to change all that.

Series 1 engines from 92-94 non-supercharged and 92-95 supercharged don't need an extension.

He'* a 98 SE.
Advocate1617, I think you're confused on the silicone coupler, and the bit of scrap extra wire you need to lengthen the IAT leads.

The silicone coupler is the rubbery-hose thing that connects the Autozone Rice Pipe to the Throttle Body. Yes, the rice pipe comes with one, but it'* not the right size for your throttle body, it'* sized for a Honda Civic. So you need one that is around 4" diameter to fit the throttle body, then it steps down like a short funnel to 3" diameter to fit the Autozone Rice Pipe. You want a silicone one, because it will flex as your engine torques in the engine bay (and trust us, it can torque around in there A LOT. There'* a video on the site somewhere that is very convincing!). The proper sized Silicone coupler is a little hard to find, which is why we provide a link for it so you can order it. I wound up just calling the place and ordering it over the phone, they told me what colors they had in stock (blue and black) and I selected black.

You attach that coupler using a pair of hose clamps. You get two 3" diameter ones with the Autozone rice pipe, so use one of those for the coupler-to-ricepipe connection, and you'll need to buy a 4" diameter one for the coupler-to-throttle body connection. Just get one in the plumbing section of any hardware store. I think I spent $0.99 on mine.

For wires to lengthen the IAT, you just need to lengthen two wires by around a foot or so. The wires are maybe 18 or 20 gauge, so any common zip-cord will be fine. The factory wires happen to be yellow and black, and I happened to have a scrap power extension cable for a computer hard drive, the kind that has four wires; typically black, yellow, yellow, and red; and I just cannibalized the yellow and black wires out of it to keep the color coding the same, because I'm anal that way. I just spliced them in with ordinary crimp connectors. You could solder the connections if you wanted to, it'* no big deal.

As for your pipes, since you ran over a transmission, you'll need whatever you need. If you trust the Atlas guy and he showed you why your parts are bad, then get what you need and salvage what you can. If you have access to a salvage yard for a stock Bonneville exhaust, you'll get the benefits of stainless. Hey at least your muffler, tips, and resonator will be stainless!

hey bugsi thanks a lot man!
Useful stuff in there!
Well, Im going to order my exhaust components and the silicone coupler tonight, as well as drive over to home depot to buy the hose clamp and find some wire that will work. Im pretty anal too, so hopefully I can find a yellow and black one.

Anyways, the last thing is I might need a little help with the intake installation, but probably not. It seems pretty simple. But, if I do, I'll post it once I get all the pieces.

I'm also going to be doing some other work on my car in the near future, so I'll definitely be coming to you for help! Thanks, bugsi - look for me on future projects, as I'm sure I will look for you when I have a problem or question!

Advocate, PLEASE put your year and trim level in your signature. Please?

Bugsi, I can scroll and find out as well as the next guy, but it gets tiring. We need that info in the signature. Including your mods when you do them.

Yeah, I was just going to say the same thing.

Fill out your sig file, we NEED that in order to know what you've got. Just look at any of ours for an example. It'* okay that you don't have any mods (really, it'* okay!). But at a bare minimum put the year and trim level of your Bonneville. If you don't post a picture too, then include anything you think is interesting, such as the color, wheel style, etc.

We really do need that, to quickly answer your questions.
I know you're new here, and that'* okay, we were all new once. I know the feeling of not knowing what to do, or where to get what parts, when everyone else seems to know what they're doing. I've asked a lot of the same questions you've asked, and agonized over doing the simplest modifications. It took me a good long time before I changed anything on my Bonneville from stock, and I remain pretty discriminating over making any major changes. But the dual exhaust and intake have given my SE similar power to my wife'* Grand Prix GT (which has dual exhaust stock), and made it more fun to drive. My next upgrade planned is the larger sway bars and Energy suspension end links. I'm sure I'll do a writeup on that too, although I plan on letting a shop install them and do an alignment at the same time.

But fill out your sig file! Just click on the "Profile" link at the top of the page, and fill out the "Signature" section.

K got the sig done...Sorry bout that guys

An update, I got all the parts in for the intake except the silcone reducer, which is being shipped today...hopefully by monday will start work on that.
I already cut the autozone pipe down by 4", other than that, I'm just waiting for the reducer. I was wondering...I noticed a 3"-4" silicone hose connector thingy in the home depot plumbing department that looks exactly like that reducer...Would that work? I already bought the reducer so it doesn't really matter, but I was just wondering.

Exhaust parts have all been purchased and are also in the process of being shipped..