The intake duct on my 94 XG ute seems ridiculously small for the size of the engine. At its narrowest it must be only 20cm sq. I want to put a bigger duct on it but it seems the current duct shape is so small cause it's the only shape that fits. Has anyone been able to fit a bigger duct without destroying the filter box? I know pod filters can be put in but not how a similar size duct is put in so only cold air gets through.

i would try and make an XH snorkel fit...

You could try to cut up a xr6t snorkel >:D

I had a look and the XH snorkel won't fit, the engine bay panels behind the radiator on the XG run right up to the bonnet leaving no room. I was thinking of taking the box out and putting a pod filter on behind the headlight. Do pod filters have to be put in a box thought for rego? If so, does covering it with a larger diameter pipe get around this? It seems whatever I do with the box will only allow a small intake duct.

Played around with a heap of different ideas, and the simplest/ best idea i came up with was:

The plastic pipe that curls from the top of the air box to the front, i cut in half (before it starts to restrict).

Then i clamped a large 90deg rubber hose (old xf intake) to the cut pipe, this then went around to the back of the headlight.

Sounds a bit bodgy, but looks standard and breaths a heap better.

After looking at it for a while that's exactly what I thought about doing. Good to hear it worked well for someone else!