homemade intake

[SolaraPatrick]

I'm an Aerospace Engineer, what are you? stupid

Aerospace engineer? Talking about NASA rockets and stuff? So your the reason for all those NASA problems and plane problems.


Seriously, You can be a brain surgeon or what ever but in the end we don't give a screw.

WIND TUNNELS FOR ME, NOT ROCKETS

[Sebas007]

I've made a kind of SRI extension...I mesured all the temp at different speed at 3 different spots. My result are posted somewhere in the "blue monster". The temp difference was not big enough to make it thru the back of the fog. I put a temp sensor on the stock CP-e filter, an other one behind the fog driver's side and an other one on the stock battery...where my filter is sitting now. I got a difference of 25F degrees between stock an new emplacement ! I finished with this...
http://www.solaraguy.org/viewtopic.php?t=34705
http://www.solaraguy.org/viewtopic.php?t=34577

It is the route I choose to take but was not cheap...need to make a kind of shield to make even more effective...but bottom line I'll never get huge power gain...maybe 2% power increase like I calculated while back.




"blue monster" = refering to the SG website

...
I wonder what tuning changes would (if any) be needed on a CP-e made into a CAI.

I don't think the air density difference would be big enough to change any setup. I even keep my extension in winter...it makes good !

[Sebas007]

There is the post I was talking about...

Day temp = 78.8
Temp are in F and Speed in MPH (just for you...Americans ! I first make it in metric...I copy it and had the formula to get in US)


S1 = Sensor 1 located in the fog light area
S2 = Sensor 2 located in the CP-e SRI area
S3 = Sensor 3 located in front of the battery

Code: Select all

Speed = 0 MPH (Idle)
    Time (sec)   S1       S2       S3     S2-S1   S2-S3
Test 01   040   81.68   114.08   101.66   32.40   12.42
Test 02   080   84.20   115.34   098.42   31.14   16.92
Test 03   120   84.92   116.78   095.90   31.86   20.88
Test 04   160   86.18   117.68   094.82   31.50   22.86
Test 05   200   87.26   119.30   094.64   32.04   24.66
Test 06   240   88.52   121.82   094.46   33.30   27.36
Test 07   280   90.14   122.00   094.64   31.86   27.36
Average   000   00.00   000.00   000.00   32.01   21.78
                                                                   

Speed = 37 MPH (60KM/H)
    Time (sec)   S1       S2       S3     S2-S1   S2-S3
Test 01   040   84.56   109.76   101.66   25.20   08.10
Test 02   080   82.22   121.28   098.42   39.06   22.86
Test 03   120   81.86   121.28   095.90   39.42   25.38
Test 04   160   81.86   120.92   094.82   39.06   26.10
Test 05   200   81.86   120.20   093.74   38.34   26.46
Test 06   240   81.86   120.02   093.02   38.16   27.00
Average   000   00.00   000.00   000.00   36.54   22.65



Speed = 62 MPH (100KM/H)
    Time (sec)   S1       S2       S3     S2-S1   S2-S3
Test 01   040   86.00   113.72   092.30   27.72   21.42
Test 02   080   81.86   112.82   091.22   30.96   21.60
Test 03   120   79.70   117.86   090.50   38.16   27.36
Test 04   160   79.88   115.88   089.78   36.00   26.10
Test 05   200   79.70   114.62   089.24   34.92   25.38
Test 06   240   79.70   113.72   088.70   34.02   25.02
Test 07   280   79.70   113.18   088.70   33.48   24.48
Test 08   320   79.52   112.64   088.52   33.12   24.12
Test 09   360   79.52   112.64   087.26   33.12   25.38
Test 10   400   79.34   112.46   086.72   33.12   25.74
Test 11   440   79.52   112.64   086.00   33.12   26.64
Test 12   480   79.34   112.46   085.82   33.12   26.64
Test 13   520   79.52   112.28   085.64   32.76   26.64
Test 14   560   79.34   112.64   085.46   33.30   27.18
Average   000   00.00   000.00   000.00   33.35   25.26


Speed = 75 MPH (120KM/H)
    Time (sec)   S1       S2     S2-S1
Test 01   040   80.06   111.20   31.14
Test 02   080   80.24   112.28   32.04
Test 03   120   80.60   111.92   31.32
Test 04   160   81.14   111.20   30.06
Test 05   200   80.96   109.94   28.98
Test 06   240   80.60   108.68   28.08
Test 07   280   80.24   107.60   27.36
Average   000   00.00   000.00   29.85


Bottom line
- More you go faster less the difference between the CP-e SRI area air temp and fog area temp is big. Same tihng with the front of battery area. The average is fu'cked because of the Test 1 at 37 MPH. Air flow is strong eliminating more hot air.

- The potential gain is always bigger in the fog area but remains way more complicated and more restrictive to reach then the front battery area.

- Front of battery area seems to have a good potential and is very easy to reach. It would surely help installing some heat shield and air deflector in the fog area (it would be a bit better).

- Relative humdity is not such a big parameter...was always the same for all the test (fog were always twice %humidity then the CP-e SRI area was)

- Thumb rule : for each 5F diff you got 1% more air dendity. 4% air density = 3% more power (hp).

http://www.hardtail.com/techtips/airdensity.html

Roughly...

Fog area temp potential give around 4.95% more power (hp)
Average of the 3 average (37, 62, 75 MPH) = 33F diff
(33/5) = 6.6% more air density
6.6/ ?? = 4/3
(6.6*3)/4 = 4.95% more power


Front battery area temp potential give around 3.75% more power (hp)
Average of the 2 average (37, 62 MPH (ignoring test 1)) = 25F diff
(25/5) = 5% more air density
5/ ?? = 4/3
(5*3)/4 = 3.75% more power


In my case I evalute I have around 240 hp
CAI in fog area could give around 12 hp at peak but would improve all the RPM band power.
240*0.0495=11.88 hp

CAI in front of the battery area could give around 9 hp at peak but would improve also all the RPM band power
240*0.0375=9 hp

Last thing to check...restriction of the CAI tubing itself. Need to get calculation of my friend engineer...but for many purpose (complexity, restriction, unfriendly install/uninstall) I think to make it like a Long SRI ! Will get colder air and be very easy to make, install and everything.

[PXLpainter]

I improved my stock intake by cutting out the sides of the box (beneath the filter...obviously) and replaced the filter with the K&N model. My question is... between the K&N filter and the mass flow sensor, there is another filter attached to the bottom of the upper box... is there anyway to remove this filter? I think that the K&N filter being between the sensor and the ambient air should be enough. Thank you.

Since most these clowns responding have been Gen 1-ers, I'll actually answer your question from experience.

Most of us Gen 2ers have gone this route once before we got SRIs (Short Ram Intakes like Injen or CPE) - but since it was so long ago that we've discussed it, I can't find the discussions in the search myself.

You can use an X-Acto knife or razor blade to cut the white damper/baffle out of the top of the airbox without breaking anything. As far as cutting a hole in the side of the airbox, I did that on my '01 Tundra and it helped quite a bit. I'd say if you don't need to return to stock down the line, then go ahead and experiment with it. Who's it gonna hurt anyway?

Next step though would be to get a CP-e though - you'll definitely notice some HP gains going that route.

[Down2TheC]

Then you might as well just chop the box off after the MAF and hoseclamp a cone filter on there. That's cheap and it would be the same as buying an Injen.

With the existing K&N you could lose everything upstream of the the filter housing and reduce the flow restrictions. You could even chop the airbox in half so you just have the rim to clamp over the filter to keep it in. Filter would be exposed and might get mucked up quicker, but you've taken it down to the essentials. (and the mounting would have to be creative)

[SolaraPatrick]

I am unable to cut off the box after the MAF. The part of the tube where the MAF is located, is part of the box. I noticed a difference with what I did. I cut holes in the side only, just so the k&n filter would stay cleaner. I may not even buy a cai when one is availible.

Thank you all for your comments.