Just a bit of background. I'm a mechanical engineer with a background in fluid /heat transfer. I didn't really like a lot of the intakes on the market since most either sucked hot air, or were made from flimsy materials. So I set out to fabricate my own for the purpose of: 1. Function like the stock setup 2. make a better sound than the stock setup. 3. look good.

This is what I came up with. It is heavy gauge stainless steel (#7 polish) and will allow for use of the stock panel filter, or a K&N cone. Video clips and process photos to follow soon.
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Looks cool but why the steel? Are you not worried about weight? And would it not transfer just as much if not more being steel instead of say another material like aluminum.

 

plastic would transfer less heat than stainless or aluminum

 

I used stainless for two reasons.

1. It's readily available at my shop
2. It has a lower thermal conductivity than aluminum. It also is more durable.

The weight savings we are talking about is minimal vs. aluminum in a piece this size. A large drink at the drive thru probably weighs more.

 

That is correct. But using plastic would defeat the goals I set out for.

 

 

good work & super clean!!! I'll take one!
what size cone is in there?

 

Ok but still steel holds onto that heat longer than aluminum does.

 

I'm a little lost. Is it the tube from an alta intake with the factory box with a different top on it and a cone filter?

 

You need gas!

Cool DIY project though.

 

Having never seen an Alta intake in person, I wouldn't know if the silicone elbow is the same or not. The one I used is an off the shelf part, nothing special.

Yes this uses the stock intake box bottom with a new top and a 4" OD cone filter, just like the JCW. In my opinion, this is the most efficient setup since the box is still pressurized, the filter isn't directly exposed to hot engine bay air, and it uses the factory cold air 'snorkel' that grabs air from the front of the car. From what I can tell on the Alta, the connection is there for the snorkel, but there is nothing to guarantee the air up front is getting to the filter.

All that being said, it's been beaten to death that the factory ECU is not going to allow for huge gains with an intake. I just didn't want to lose power.

 

looks amazing.



....and Simple Green is your friend

 

thanks! and haha, you are right. i should be embarrassed for posting pics of the engine bay looking like that.

 

short engineering process video.

 

The box top looks really nicely done, but I still don't understand why it's an advantage, based on the photos. Is the cone filter inside the SS box? Do they not make a flat OEM style K&N type filter?

soif I understand correctly, you fabbed the SS box to hold a cone filter, but the "cold" part of the intake is in another photo?

What am I missing here?

This is an S, right?

And sorry to say I completely missed the point of your in-car vid, other than it was cool to see you driving under what I assume is the Chicago El? I couldn't hear anything but noise, let alone your engine.........

 

It looks sweet man! great job

 

it would look better if it was not triangular, it may just be on the video but it does not look like it is a mirror image of itself

 

i like it

 

1. There is a cone filter inside the box top. The cone filter has a larger surface area than the flat OEM filter.

2. They do make a K&N panel filter that fits. It's more expensive, but would achieve the same results.

I also went with a cone for a future modification that is in the works. The panel would not allow for the future mod.

3. The 'cold' part that everyone refers to is the fact that the system is sealed, just like factory. It's pulling outside air from the cavity behind the grill and fog light area using the factory 'snorkel'. 'Cold' only refers to sucking ambient outside air, regardless of its temperature. The open filter systems that I've seen, all suck the 'hot' engine air. I've seen estimates that for every 10 degree drop in temp, an engine can gain 1hp. How true that is for out cars, I do not know. I'm not all that concerned either to be honest, but that theory still applies I guess. Air is more dense as it gets colder.

4. It's an 'S'.

5. I apologize for the low quality audio in the video. I was using a point-and-shoot. If you listen closely, you can hear the bypass valve a little better than stock, and also the inrush of air. I happen to like hearing it, some may not. That was the point.

 

looks like he was driving on Lower Wacker Dr in the Chicago "Loop". Which is a fav for car guys due to the "in-a-box" sound you can get and there's a few fun corners too.

 

Good fab work.

 

O RLY?

 

I'm with minidave on this....

amazing work and design process...but seemed like it was a lot for nothing? It's basically the the same thing as a JCW box, except that its metal which is going to get hotter than the plastic would.

BUT..... you clearly had a distinct set of intentions and knew exactly what you wanted, so props to you for going out and achieving what you set out to do!

 

pretty sure it cost him alot less than the jcw and looks much better IMHO and the best part is that its the only one out there

 

I did not mean to denigrate the OP's work in any way, I was only trying to better understand what he was trying to accomplish. Sorry if it didn't come out that way........

I was looking to see if he'd done something different on the snorkel end of the intake too. He's right, it the intake air comes from under the hood instead of from in front of the car, it will be "pre-heated"