7 replies to this topic

[11R/TnBLK]

Time to share a Little project I completed in August /Sept. Decided to lower Intake temps and introduce/force more cold air into my 6.4.

 

How to do this while maintaining my "Sleeper" mentality? My idea was to use the Fog lamp bezel on my M11 as the Air intake.. Mind you this is not a "Dryer vent line" hook up. Like Most  other Gear heads on this forum, it had to be clean, professional, and functional.

 

Started with the API Cold air kit, which has ben on the car since early '12. but it needed to be refined..

 

I started with removing the bezel, cutting, and fabricating a cold air duct from Carbon Fiber.

 

Using Green Foam as the Inner mold, I shaped it to conform to the exterior dimension Of the bezel:

 IMG-20140625-00004.jpg   200.54KB   10 downloads

 IMG-20140625-00005.jpg   209.05KB   9 downloads  IMG-20140625-00006.jpg   195.39KB   9 downloads

 

Then to make the CF intake duct, fab'd from 1 layer of 45* pre-preg CF sandwiched between 2 layers of 90*:

 IMG-20140627-00007.jpg   220.99KB   9 downloads  IMG-20140627-00008.jpg   270.26KB   9 downloads

 

Put it under vacuum and cooked for an hour or so

 IMG-20140627-00009 (2).jpg   233.26KB   9 downloads

 

trimmed up and ready to be bonded to the bezel, using AIRTECH 3100 Binary epoxy, vacuumed and cooked @ 150*f for  :15, under 20 hg. 

Intake duct complete:

 Inlet scoop.JPG   146.24KB   9 downloads  Inlet Scoop -Side.JPG   144.48KB   9 downloads

 

For the engine bay,I formed a True Cold Air box from Aluminum, using the API piece as the start point, sealing it off from engine bay heat and "dirty" air. Bottom of the box first after opening up the OEM metal work a little wider

 Bottom Plate-Fabricated.JPG   130.82KB   9 downloads

 

Using a Ricer velocity stack as a Plenum:

 Cut Velocity Stack.JPG   185.81KB   9 downloads  Alum. plate w- Velocity stack.JPG   123.47KB   9 downloads

 

Then the rest of the  Cold Air Box fab work, getting the radius along the core support  correct was a patience test:

 SAM_0004.JPG   105.3KB   9 downloads  SAM_0005.JPG   128.42KB   9 downloads  SAM_0006.JPG   130.66KB   9 downloads  SAM_0007.JPG   100.67KB   9 downloads  SAM_0008.JPG   73.39KB   9 downloads  SAM_0009.JPG   94.95KB   9 downloads

 SAM_0013.JPG   124.21KB   9 downloads

 

Finished up by lining the Box and CF lid with DEI heat mat,(Killer stuff):

 Cold Box -lined 2.JPG   544.43KB   10 downloads  Cold Box -Lined 1.JPG   530.88KB   10 downloads  2 Installed Cold Box.JPG   534.1KB   10 downloads  1 Installed Cold Box, fender lined.JPG   544.43KB   10 downloads

 SAM_0011 (2).JPG   528.52KB   11 downloads

 

The Intake tract, using .100" alum tube and readily available silicone connectors:

 Intake track.JPG   119.98KB   10 downloads

 

And finally,The "Sleeper" intake bezel: You cannot see the "Blue" when you look at the car"

 OEM location.JPG   164.99KB   10 downloads  OEM Location -2.JPG   107.47KB   10 downloads

 

The finished product is pretty sweet. Our rudimentary wind tunnel consisted of the car in a booth, Multiple high velocity fans and packing "Popcorn". It was sucked/pushed right, in filling the Box rapidly.Intake temps dropped drastically,(air temps monitored by static temp gauge, and pulled from log) as soon as I find the numbers I will share) as it was nearing the end of summer when I finished. I had bounced a couple ideas off Chris @LMI (Thank You Brother), and it just all clicked.

 

No Dyno #'s since the last Time AJ worked his magic, as there are a few other things I am prepping for.

Seat of the pants tells a good tale. once she's up on the stall (approx. 3800) it pulls Harder thru the midrange, and seems to get to max shift RPM sooner. My mpg increased by a full gallon (when I'm not "in"it).

 

Wanted to share.

 

 

[novawagonmaster]

Nice work!

[11R/TnBLK]

Thank you.

legmaker is a really good cat to talk with, no BS.

[legmaker]

this project came out nice.  i am not usually real big on boxes and "shield" because they are usually always half assed and don't really do anything.  the biggest difference with this is the fact it is almost completely sealed due to the nice front and bottom sections that were built to the box, that did not exist before.  the craftsmanship is very good as well.  my only suggestion to help with increased flow, would be to enlarge the exit opening of the "funnel" made to connect to the fog bezel, so that it was a matching OD of the connecting alum pipe to the air inlet opening/velocity stack.

 

lots of work in this......... not for the avg guy.  as i said in our emails...... well done my friend! 

[11R/TnBLK]

^^^^  Yes.. as soon as I have a new bezel, I kept it 4.0" from intake to box. Bonding the larger I.D. CF duct to the bezel is the challenge, keeping the smooth contour. Making it, piece of cake, kind of.. I made the CF intake tract run all the way to the plenum, using only one silicone 4'' x 4" coupling.

 

Your guidance, is spot on.

[jettech104]

Very cool DIY project!! Looks great!!

[El Diablo]

Nice job ! Very professional looking.

[11R/TnBLK]

Compliments from this crowd... priceless.

very much appreciated