if you want to install insuflex in the door panels, you'll have to stick it onto the plastic panel itself
if you stick it inside the metal cavity, it will accumulate dirt and promote rust
insulating door panels for heat is not worth the effort as most of the heat comes through the roof and the front and rear glasses
having a good tint, using sunshields for front and back glasses, installing insuflex on the roof metal and cracking your window open about 1cm when parked would be a much better option for heat reduction

if you still insist on removing the door panels and installing your insuflex, heres how you do it

1. the door latch handle has a little flap in its cavity
use a test pen to flip it open and remove the screw behind it
2. you'll find 1 more screw in the handle cavity
remove that and along with the handle cup which the screw is holding down too
3. look sideways at your window winder
you will see a spring clip holding in
use a test pen to push it off
this can be achieved by pushing on one of the clip tips
if pushing on one tip doesnt work, try pushing on the other
this has always worked for me
4. now slowly start to pop the panel off the door starting from one of the botton corners moving towards the top
once you reach the top, do the same from the other corner
5. unhook it from the window sill and you are done
6. try not to drop it face down as this plastic scratches very easily

if you are familiar with the system, this whole process should take no more than 5minutes

sorry bro
real busy and always outstation lately
will try to get u a description soon

well, i was looking at it but i'll lose sooo much booth space
the new saga on the other hand has a booth that was designed to fit in a gas tank
thats y the booth is so deep
its so that when that car replaces the taxis, it wont be like today's taxis where all you can put in the booth is your hand lugage
your check-in lugage (i.e. the big stuff) has to go in the back seat
so rediculous
but as the price of petrol increases, im seriously contemplating if i should sacrifice my booth to save money
only prob is there are a lot of 'copy' systems out there being marketed as 'originals'
they are made locally in ppl's workshops with little or no QC
they are copied from the design of the ori imported systems

as this is a highly hazardous system, i really want to get an ori setup installed by a pro
i also want a composite tank to save on weight
the old metal tank versions are so heavy
the composite tank also endures crashes better

bro
to remove the roof panel:

- unscrew your rear view mirror, and the 2 sun visors at the front of your car.
- unclip the cabin light cover. you can use your hands. there are 4 clips iinm, one on each corner
- unscrew the cabin light housing
- unscrew the passanger roof handles. u'll have to unclip the covers for the screw points. just lever them out with your fingers
- pull out all the push clips along the back (not sure if there are any on the front) basically remove them all. they look like little plastic discs on the roof. i used a large edge cutter as it has to very solid parallel flat surfaces which i can wedge under two sides of the disc. then lever them out gently without damaging the roof plastic. DO NOT CUT!!!. just use it as a lever
- the roof should come off easily

before you glue your insuflex or other choice of insulation onto the roof metal, you might want to re-route the ariel and cabin light wires.
mine were pretty messy
also remember to leave access holes in the insulation for all connection points. e.g. the arial wire
also, remove the arial by unscrewing it from the inside
clean the rubber foot and roof properly
apply a little high temp silicone on the foot which will be sitting on the roof surface
screw back the arial firmly (do not overtighten as this will crush and distort the rubber foot
remember to check that the arial is aligned with the car body

this is a potential leakage point in the car so might as well prevent the leak before it happens

remember to use insulation which is not thick
if the insulation is too thick, you will have trouble fixing the roof cover back on as the clips and all will be too short
and you will also risk it popping out in the future due to too much stress on the anchor points

This post has been edited by neosaint99: Jun 19 2008, 08:53 AM

ahaha
thats an idea
b incase need to take ppl then susah
must ask them to sit on metal

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Added on July 23, 2008, 5:14 pmso hows ur proj going bro?

This post has been edited by neosaint99: Jul 23 2008, 05:14 PM

very chunted bro
your interior looks super modded
hahaha

sponge part should face up bro
the smooth part face down so the glue can get a good grip on the insuflex

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Added on January 14, 2009, 7:50 pmi using DIY NGK platinum side gapped plugs pun
damn good man

This post has been edited by neosaint99: Jan 14 2009, 07:50 PM

Dont worry,...no effect on air flow
the main benefit of the ori cai is that it takes air from the fender
this means it is cold (atmospheric temp) and also clean
...if the ducts just face forward e.g. from a hole in the front bumper, then filter gets dirty faster as its essentially a vacuum cleaner for all the dust n dirt that one drives through on a daily basis

as far as power/efficiency diff, i'd say there is none...even forward facing types (some say coz driving forward into the air increases air flow) will not be noticable coz the diff in pressure is too low for us to 'feel'

one thing that may be noticed with the ori cai is longer filter life which, if one doesnt change often will definitely translate into better efficiency as a dirty filter can quite significantly affect efficiency

suggested change interval: 5000km

the filter is only RM7 anywayz...

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Added on April 28, 2011, 10:37 amgot it in seremban
one of the accesory shops on jalan zaaba, past the fire station
important thing to note about this type is that the bearings must be good. when you change your shocks, take the bar to a shop and get new bearings hydraulically pressed in
using a hammer will just ruin the replacements from day one

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Added on April 28, 2011, 10:37 amThanks bro!
glad to see posts on the thread again

This post has been edited by neosaint99: Apr 28 2011, 01:20 PM

Insulation should be still available at the shop
just need a weekend and somebody to help

CAI dont think got anymore at ploton locations...after i bought it a few ppl asked me...they tried to get from the Glenmarie spare parts centre (where i got mine) but no more stock...
Maybe can try some normal spare part shops...just might get lucky and find one

Yeap, after market CAI can work too. Only slight difficulty may be getting the CAI to fit into the fender hole (it is square)...but I'm sure some creative solutions will be found

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Added on January 21, 2012, 3:20 pmYeap, thats the place. The address for the shop is on the 1st page in the mod description, just click to expand

Wah, price gone up d arr....well...still worth it...the saga is like a frekkin milo tin without damping...

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Added on January 21, 2012, 3:21 pmGuys, whats DRL?

This post has been edited by neosaint99: Jan 21 2012, 03:23 PM

[quote=Lowenkreuz,Jan 21 2012, 03:24 PM]
[quote=neosaint99,Jan 21 2012, 03:18 PM]
Yeap, after market CAI can work too. Only slight difficulty may be getting the CAI to fit into the fender hole (it is square)...but I'm sure some creative solutions will be found

But isn't there a bigger round hole also??? I'm thinking maybe use that hole instead of the smaller square one.

[/quote]

Oh yes!...you are absolutely right. There is a wire going through it, if my memory serves (cant remember what it is for tho). I made an insuflex plug for it. If the round hole is now used for CAI, then just make the plug for the square hole. Assuming the CAI duct is smaller than the round hole, one could make a sleeve out of Insuflex to hole the duct in place. If its snug enough, it will click in really well coz the rings of the duct will 'clip' into the rim of the hole

Try to move the wire to run through the square hole then...afraid it will get pinched between the duct and the rim and ultimately get cut through...

The only other meter i installed was the multi display clock/volt/temperature meter...can see it in my mod list I just used the same point in the firewall through which i passed the vacuum hose...

not sure off the top of my head...
will have another look at it tomorrow...if you have to take off the whole fender, then definitely not worth it
hopefully there is a simpler solution...lets see how it goes...else will have to put a thick sleeve or something around the wire where it will be rubbing the rim so as to avoid friction wear

Puspakom is going to ban tints?....thats really crap man
if so, we are going to become like brunei
we live in a frekkin blazing hot country and we cant tint our car to keep it cool?...only 'special people'...a.k.a. the "elite" of the country (and i say this with the utmost sarcasm and scorn), will be allowed to tint?...
frekkin tyrannical dictatorship....only for itself...never for the people...

glad it was helpful for you
its such a common problem and yet proton refused to rectify the problem - with an extremely economical and proven method...right up till the last iswara rolled off the production line

do let me know if the mod solved your problem and how much it cost you
its good to keep the readers up to date on the most recent pricing