Gen6 Camaro Sound Tube Defeat Firewall Plug

thingiverse

I searched everywhere for a long-term solution to neatly remove the sound tube from my 2017 V6 Camaro, but I was far from satisfied with anything I found commercially. The intake plugs on a V8 are a different size than those on a V6, and the V6 intake tube opening is 30mm in diameter. This means that the intake caps shown here will not work for a V8 engine. However, the firewall plug will work on either a V6 or a V8. I recently posted an alternate version of this set that is simpler to print and install. It also includes intake tube plugs (several versions) that fit V8 intake tubes (24mm openings). You can find it at https://www.thingiverse.com/thing:3267691. First, the firewall plug: This will fit any Gen 6 Camaro with a V6 or V8 engine. I'm not sure about other vehicles, but if you have one equipped with a "sound tube" that has a firewall end like the one shown, this should work. I designed and printed a plug to replace the firewall end of the sound tube and plugged the air intake tube with a rubber cap originally (various sources sell them as chair leg tips). Later on, I made a custom cap for the air intake end (see below). The original tube end has two tabs that engage notches in the edge of the firewall hole. When designing my replacement, I duplicated their positions and sizes and added some extra strength to ensure they wouldn't break off. This Dorman rubber plug is a very tight fit, but with a thin film of lubricant, it can be stuffed completely up into the intake pipe hole so that it is flush with the outer edge. Examples of lubricants include Vaseline or white grease. Just barely wet the rubber plug so it looks shiny. Use lubricants sparingly or the plug can pop out when you tighten it up!! Don't use the large metal washer they supply with it and use the printed cap instead. Put the cap over the plug's center bolt and push the cap firmly onto the intake pipe. Then, use the original nut to secure the cap in place and to expand the rubber plug so it won't slide out. Tighten so it is snug and won't come undone but don't get crazy with the torque on it or you could split the intake pipe (which is an expensive part). If this causes you any potential concern, please check out my other posting on this subject which contains two plugs that are much more gentle to the intake duct and don't require purchasing the rubber stopper at all. You can find it at https://www.thingiverse.com/thing:3267691. The end result looks more like a "factory" thing and is very inconspicuous. Most people would never realize it was not original if you didn't tell them. As with the firewall plug, I printed it in ABS, sanded it lightly and vapor polished it so that it looks slick and molded. The camera flash on the photo makes it look rather crude, but it really does just sort of disappear underneath the intake tube. If in doubt, paint it with some matte or flat black paint. Don't be surprised if you need to re-tighten it after a few days because the rubber plug will change shape a bit, but it shouldn't fall out. I had to tighten mine slightly twice in about 3000 miles, but since then I have replaced the intake tube plug and cover with a different design (see https://www.thingiverse.com/thing:3267691). It is even simpler to install and has not loosened at all from the time of installation. There is also a second version of the intake tube plug which should allow you to use the original washer as supplied with a Dorman 02602 rubber plug. It is 2mm larger in diameter and is slightly thicker on the base for added strength. But again, the versions I posted on the other link are easier to install, although the covers shown here could be used by gluing or screwing them to the plug sets at the other link. Again, neither of these intake plugs will work for V8 cars. Please see my other posting link for updates on a V8 version. Thanks very much for viewing this.