The step numbers below correspond to the steps in the Safari installation guide:
Steps 1 and 2:
- The easiest order for removal is:
- Remove the mudflap
- Remove the inner guard liner
- Remove the air entry duct (inside the guard, retained by 3x bolts)
- Remove the air cleaner assembly
- Remove the air entry flange (from the engine bay.)
- Removing the front wheel or turning to right-lock will enable access to remove the torx-head screws retaining the mudflap;
- The plastic clips retaining the inner guard liner are re-usable, simply lever the centre out and the clips are easily removed.
- Make it easier to see the required depth on the step drill by marking the 16mm step with a felt pen;
- 114mm is a standard holesaw for running sewer pipes, so they're readily available on eBay or from a plumbing supply store;
- The 114mm holesaw requires a very slow speed. Use a drill with a geared low speed (rather than just electronic variable speed) if you have one available;
- An air body saw is the best choice for expanding the air entry hole. If you don't have one you could also use a jigsaw. However, be sure to thoroughly protect the surrounding paintwork with several layers of masking tape, to prevent the saw skids scratching the surface.
- Don't forget to deburr and paint the all of the holes, or they'll rust out;
- Deburring can be performed with a deburring tool, or a round/half-round file.
At this point (with the sealant handy) I also completed Step 13 (sealing of the airbox drain openings), which Safari list as optional. The downside being that any water that enters the airbox (eg: heavy rain) cannot drain out. However, leaving the holes open risks water entering the engine during long, deep water crossings. I chose to seal the openings.
Due to the design of the A pillar, you cannot use a step drill to expand the mounting holes to 8mm (You risk drilling through the inner layer of the pillar). You'll have to use a standard 8mm drill bit.
Water driving safety tips
A snorkel is not an excuse for taking excessive risks, particularly in water. Many people have died or been injured driving through water that's flowing too fast, or is too deep. Use extreme caution when negotiating flowing or deep water. If you don't know how deep the water is, don't attempt to cross it.