Turbo Heat Shield / Cold Air Feed / Cone Filter Install / Airbox Mods

[Rusty]

Following on from this thread I've decided to design and make a turbo, downpipe and wastegate heat shield that can fit in place with the stock airbox with the aim of further reducing air temps in the inlet.

I'll also be looking at making a substantial heatshield for use with a cone filter to shield it from the hot air, this will aim to completely cover the k24 and EM and provide a large area to allow a decent sized filter.

I'll also be taking apart the front of the car, when the weather is better, to see if I can design a strut that allows for a 4" flexi air feed from the front of the car to the inlet of the airbox, this looks to be possible as the aperture measures about 4.5" x 3".

I'll keep the thread updated with my progress and if I manage to make somethign nice then I'll offer the product under my K24racing guise.

Just waiting for the 1.5mm ally sheet that I purchased from ebay, a mere 1m x 0.5m

[Rusty]

I'll also be looking at fitting this in and see if I can get it to work as well as the stock airbox (silly isn't it ) The pipe was a bargain on Ebay and fits perfectly, the joiner was from the same place too. Filter was £20 off a mate years ago and is plenty big enough, I think it retails for about £60 or so, same as the K&N stuff.

Ideally I'd have a 90deg bend in silicone with a 90deg ally joiner but that was a lot more £ and the only advantage is that you can offset the bend a little and rotate it a few degrees... hardly seemed worth it.

Here's a link the the currently discounted 180deg bend

http://cgi.ebay.co.uk/80mm-3-1-8-Sil...item439bf8f0de

Even cheaper again!

http://cgi.ebay.co.uk/80mm-3-1-8-ID-...item1e5862677d

I stupidly purchased a 76mm bend and joiner and the MAF is 80mm. So have bought the cheaper one, only £23 for a 180deg bend and joiner!

[Rusty]

Just been looking at filters.

I'm using a Green Powerflow CA1.80 filter, seems to retail in the £80 bracket but it does have a front cone that would be beneficial in the S2 due to the air feed direction.

I had a look at the basic Green filters and the K4.80 seems to be the same size and is cheeper and there's the straight sided B4.80 (name made me laugh a little). Then there's a twin cone effort in the same size cone, I think that would be my pick based on cost and performance.

In K&N there are a myriad of filters to choose from, for the 80mm options I've found the RU9004 (straight, £40 ish), RE0810 (cone, £42) and RC5100 (cone, £41). All are the classic K&N style with end plate, this would impede flow a little from where you want it most so I think I'd so elsewhere.

ITG do some big filters and are available through Merlin Motorsport, the JC60-80 is a big straight sided effort, priced at £65 it's in the middle and there's also the JC60-78 which is similarly sized and conical. Both should work well and I'm certain that there are a few in use on here, just depends if you like the foam idea or not...

[Error404]

I've got an Aepxi dry filter on my CQ that is half the size of those above and good for 450+hp - might make life easier in terms of fitting?

[Rusty]

Got a link there?

The large size isn't actually an issue as it's about the right size to support everything nicely

[Error404]

Its this type - except I got mine for £40 new and made a flange adapter

[A80Avant]

i have the apexi, the HKS mushroom and a shallow KN to try out and test. will be making a custom airbox to fit as well.

[Rusty]

Right, that's the same as I've found for £75 here (with a straight to air filter fixing).

They do seem to be the same OD but are much shorter (as you say, about half).

Ideally I'll be able to design a kit that allows a number of air filters to be used, just contains fitting parts and teh heat shield. Be interesting to see what can be done with a bit of thought.

[DJones]

This is what i have done. Cone filter is underneath, the front is open and the rear closed with the exception of some venting.

There is a 3" hole in the inner wing with a scoop that takes cold air from out side of the engine bay..

[Rusty]

Looks nice and neat. Have you got the MAF under there? You must have a non standard intake pipe too?

If I can make something similar with the MAF and stock intake then I'll be quite happy.

[Jamo]

Looks nice and neat. Have you got the MAF under there? You must have a non standard intake pipe too?

If I can make something similar with the MAF and stock intake then I'll be quite happy.

The MAF is in an alloy tube between the IC's pic in his project thread IIRC

Have you got a picture of the hole and scope made Mr Jones?

[Rusty]

Right, that figures.

I need to get some time to take a good look at the bonnet/headlight supposrt pannel. Clever Audi put it bang in the middle of the only aperture that gives a direct path to the inbox (without a few bends etc.). On an old Golf I used some fog light replaceing intakes and ran some 2.5" hose straight up to the cone filter No such luck here I think When I've looked behind the fogs there's nowt but the end of the chassis leg, space is limited, even getting some small brake cooling pipes in there wiould be difficult. Shame.

Ideally I'll keep body mods to a minimum as it's not really most peoples' cuppa tea and can lead to issues with corrosion in the future.

[DJones]

Have you got a picture of the hole and scope made Mr Jones?[/QUOTE]

Unfortunately not.. its a very simple thing though.

3" hole cut neatly with a tank cutter directly under the filter, "U" section rubber pushed on to the cut edge producing a round hole that is rubber edged (if that makes sense...) Flexiduct pushes nicely into the hole.

An air scoop 6" long x 1" tall which finishes with a round outlet that pushes on to the flexi pipe.

Nice and discreet and effective....

[Jamo]

I'm watching to see what you come up with incase my current plan can't be implemented

[Rusty]

Right, it's freezing outside (for sunny Brissol anyway) but a few things.

The idea of cutting the bonnet stay will have to be shelved as there is a torsion spring running down that plate. I will be able to trim it a bit though to improve my current inlet air feed (pictured).
There is more room than I though behind the fogs, a piece of pipe could be fitted there, say 2" with the duct helping to direct air towards the engine to bypass the chassis leg. This would require some nice blanking plates making up and a 3D structure to guide the air etc. Beyond my fabrication skills and more of a summer job TBH.
With the AC compressor moved there's a lovely tract that goes under the OE XM to engine hose and then pops up on the airbox side of the inlet hose, this could be between 3 and 4 inches and would sit gulping in air from behind the grille. With a little fabrication, a simple guide could be made to take air from along the grille a bit, say 4" or so, and thus get a little more.

Having looked and promptly p'd myself laughing at the cost of cold air feeds (£40-50!) I thought that a little British ingenuity was required

4" bass port

4" ducting hose

Not sure I need 5m of ducting really but there we go

I think that will satisfy my cold air requirement, a modified OE tract (cut and bend the bonnet stay a little and extended guide) + 4" feed from the grille.

I've got the fitting parts pretty much sorted now and a cone filter, all of which attaches neatly to the MAF.

Just got to get the turbo heat shield finished and see what can be done to insulate the cone filter as much as possible without going mad with a drill or Dremmel.

Interestingly, having looked at my drilled airbox, it's drawing air from all the right places, explains why it works pretty well IMO.