DK Wolf
09-16-2013, 03:49 PM
So I know there are little gains to be had from modding the intake much more than stock. However I'd like to build a CAI for my Miata that doesn't cost $300, and won't suck up water if it rains.
I also want one that won't be prone to heat soak too much. I eventually want to move into longer duration races and would hate to have power robbed from me with hot air getting sucked in compromising performance.
I'm working with Zerek with Zerek Fab to help me get this together. Just running it by anyone else to see if anyone has any suggestions or ideas to pitch in. But here's where it's at for now.
Car in mind for now is the NA.
Primary target was to introduce cold air, and keep hot air from getting sucked in. I wanted to build something similar to the FMII intake shield design. Although I feel it could be improved with more thermal reflective material.
reference photo
http://carphotos.cardomain.com/ride_images/2/3757/3809/21891904007_large.jpg
You can see the shield surrounding the intake, and it's fantastic. it traps the cold air being sucked in front he headlight lid into that area and potentially blocking out hot air from making its way into it. Although I wanted room for improvement for anyone with either a vented headlight lid or a Turn signal intake to allow direct ducting into that area, and the option to turn down the ducting to avoid water getting into the intake area should it rain.
As you can see, here is a shitty vent idea from a TSI into the intake chamber.
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/v/1081088_454968744610707_1268608616_n.jpg?oh=b2ec86 b9bb6f4b38e880698673d22633&oe=5239924D&__gda__=1379521561_9729fd94fba946f4c5e3940b7a42bb4 b
at either the end or the light itself you could seal off the ducting during rainy days.
Here is another picture with a generic cross over tube example of where it would go.
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/v/1081888_454968757944039_1913440399_n.jpg?oh=32f132 e4c3cea09054c9c75afa347bf1&oe=5238F922&__gda__=1379553078_50ce070d9d97cea008362c0f498002a a
I also don't know the optimal thickness for the cross over tube as that actually has a significant bearing on the powerband (I'll be on the hunt for more information, however if anyone would like to spoon feed me information, that'd be great).
I also wanted to potentially toy with the idea of just actually having the intake on the cold side altogether. Although I feel it wouldn't be appropriate to get that deep into it just yet. Maybe later on down the road after I see how this pans out.
The goal of this is to be inexpensive... and if it's good and making it is easy, I'll be more than happy to make more and probably sell it easily less than $200.
The material for the cross over tube has brought a little confusion for myself however. I would like to do aluminium as it's thermal reflective properties are pretty awesome when the exterior is polished, and it would cool quickly with its of air going in. I also wanted to see if there were any plastics options that did well against heat soak. I'm not sure about using silicone tubing as I don't know if the flex properties of the tubing will affect air flow and overall gains. But from what I understand, the intake should be as smooth as possible just like the exhaust to maximize airflow/velocity.
I will be paying out of pocket for dyno time to have Zerek test our model out to see which has the best gains, toying with a variety of piping sizes and types of intakes.
Zerek suggested using the "green intake", I don't have personal experience with them so I don't know.. he however has a pricing deal with them so it makes using them attractive. We were toying with K&N and HKS sponges etc. So I don't particularly know. Again, suggestions here would be awesome. Because we're going to end up buying a few different kinds and experimenting.
I also want one that won't be prone to heat soak too much. I eventually want to move into longer duration races and would hate to have power robbed from me with hot air getting sucked in compromising performance.
I'm working with Zerek with Zerek Fab to help me get this together. Just running it by anyone else to see if anyone has any suggestions or ideas to pitch in. But here's where it's at for now.
Car in mind for now is the NA.
Primary target was to introduce cold air, and keep hot air from getting sucked in. I wanted to build something similar to the FMII intake shield design. Although I feel it could be improved with more thermal reflective material.
reference photo
http://carphotos.cardomain.com/ride_images/2/3757/3809/21891904007_large.jpg
You can see the shield surrounding the intake, and it's fantastic. it traps the cold air being sucked in front he headlight lid into that area and potentially blocking out hot air from making its way into it. Although I wanted room for improvement for anyone with either a vented headlight lid or a Turn signal intake to allow direct ducting into that area, and the option to turn down the ducting to avoid water getting into the intake area should it rain.
As you can see, here is a shitty vent idea from a TSI into the intake chamber.
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/v/1081088_454968744610707_1268608616_n.jpg?oh=b2ec86 b9bb6f4b38e880698673d22633&oe=5239924D&__gda__=1379521561_9729fd94fba946f4c5e3940b7a42bb4 b
at either the end or the light itself you could seal off the ducting during rainy days.
Here is another picture with a generic cross over tube example of where it would go.
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/v/1081888_454968757944039_1913440399_n.jpg?oh=32f132 e4c3cea09054c9c75afa347bf1&oe=5238F922&__gda__=1379553078_50ce070d9d97cea008362c0f498002a a
I also don't know the optimal thickness for the cross over tube as that actually has a significant bearing on the powerband (I'll be on the hunt for more information, however if anyone would like to spoon feed me information, that'd be great).
I also wanted to potentially toy with the idea of just actually having the intake on the cold side altogether. Although I feel it wouldn't be appropriate to get that deep into it just yet. Maybe later on down the road after I see how this pans out.
The goal of this is to be inexpensive... and if it's good and making it is easy, I'll be more than happy to make more and probably sell it easily less than $200.
The material for the cross over tube has brought a little confusion for myself however. I would like to do aluminium as it's thermal reflective properties are pretty awesome when the exterior is polished, and it would cool quickly with its of air going in. I also wanted to see if there were any plastics options that did well against heat soak. I'm not sure about using silicone tubing as I don't know if the flex properties of the tubing will affect air flow and overall gains. But from what I understand, the intake should be as smooth as possible just like the exhaust to maximize airflow/velocity.
I will be paying out of pocket for dyno time to have Zerek test our model out to see which has the best gains, toying with a variety of piping sizes and types of intakes.
Zerek suggested using the "green intake", I don't have personal experience with them so I don't know.. he however has a pricing deal with them so it makes using them attractive. We were toying with K&N and HKS sponges etc. So I don't particularly know. Again, suggestions here would be awesome. Because we're going to end up buying a few different kinds and experimenting.