After much debate over after market CAIs, I finally decided to have a go at just modifying the OEM intake manifold to pull ambient air from behind the bulkhead below the windshield. I have been using an Alta drop in foam filter with great results. It has much more air flow than the stock paper filter and I get plenty of sound from the turbo. I have a Forge FMIC that makes a huge difference in power and throttle response, but my Scangauge II shows that the intake air temp takes a long time to cool down after heat soak buildup. It is my understanding that the Intake Air Temp is measured at the MAF and I wanted to try to pull cooler air into the airbox to keep me as close to ambient as possible.

My thought was to keep the stock air vent from the front grill and add to it by tapping into the source from behind the bulkhead. So I bought a new intake manifold elbow to work on so I could put back the stock piece if things did not work out. The part number for this piece is (13712753082) and it cost me $24. I used a piece of 2 inch flexible hose from an old shop vac to splice into the top of the elbow and connected that to a 45 degree pvc adapter ($1.50) through the bulkhead.

It took a little head scratching and a lot of tweaking to get it to fit right, but I got it done! My first test drive was late at night and the outside temp was in the low 30s. There was a nice new growl from my newly modified intake and I could hear the spool up of the turbo more distinctly as well. After a good thirty minute spirited drive around the back roads where I live I returned to the garage to see if everything was still in place. I immediately raised the bonnet and put my hand on the new hose to make sure it was still secure in the bulkhead. To my delight, not only was it still in place, it was cold! Proof positive that cool air had been pulled through under speed as the rest of the engine compartment was its normal do not touch hot temp. I have not had the opportunity to test the heat soak issue yet, but the bottom line is I'm confident that I am getting more cool air to the air box.

https://www.northamericanmotoring.co...00/MyCAI-1.jpg

https://www.northamericanmotoring.co...00/MyCAI-2.jpg

https://www.northamericanmotoring.co...00/MyCAI-3.jpg

 

Great work I like. Simple an effective, let me know what kind of results you have in warmer temps.

 

Nice work. I had a similar setup on my MC but was concerned about water making it's way into the manifold so I ran it farther to the left in the battery compartment. The cowel space is a great place to pull in outside ambient air.

 

Oxy have you started the swap yet?

 

I'm rebuilding my 914 engine after it threw a rod at my last track event so the MINI project is on the shelf for now.

 

I kept an eye on the intake air temp on the ScanGauge this morning on my way to work and noticed that during short runs at WOT the air temp would drop approximately four degrees, then return once back to an average fifteen degrees above ambient with normal throttle. Makes me think that more cooler air is pulling from the new source during heavy demand, and that there is some heating of the air coming from the front intake vent as it passes through the hot engine bay. Tomorrow morning I think I will tape off the front vent and see what results I get from just pulling intake air from under the windscreen.

 

Paleo, Great job. I will have to see it if you are going to MOTD 2010.

 

that does look great! glad to hear results. might have to give this a whirl with or without a cai

 

Shatzy - I'll be at the Dragon, what better to test out my air intake than with some good old Deal's Gap mountain air!

 

Keep us updated, I am really curious what kind of results you get. Something I my try in the near future.

 

If water is a concern K&N makes these DRY WRAPS for less than $20. supposed to be waterresistant, which should help. Also keep big leaves / insects/ ect out of the fins

 

I taped off the OEM intake vent at the bumper yesterday morning before leaving for work. I could tell from my normal monitoring of the ScanGauge IA and ambient outside temp it appeared that the IA temp was slightly lower pulling air from just the cowl area. Although the car performed as normal, the intake sound was not as deep at lower speeds as it had been with the full open air flow from both sources. Hard acceleration and WOT brought back the missing growl.

After twenty minutes of driving I pulled over, popped the bonnet, pulled off the tape from the forward vent, then got back on the road. With both front and rear vent options open the IA temp read 5 degrees warmer than pulling from the cowl only, confirming my earlier suspicions. The continuous deeper throaty sound was back too, letting me know that having both sources open does help the engine breath easier. It does tend to register a few degrees cooler IA temp at higher speeds and when I go from cruising speed to WOT the temp drops off quickly as well. All this tells me that my modified intake is getting more and cooler air under load - a good thing. Curious to see what difference it makes this summer.

 

don't suppose you have more photos and/or a diy instruction made up. i realize it's not rocket science but i think you'd know pretty well having done it now.

 

Yes, DIY instruction sounds like a good idea.

 

im debating on what one to order

 

get a dos tell clint james hunt sent you

 

Interesting................... hmmmmmmmm. Looks like it may also get rid of the issues of moisture on the filter element by NOT having the filter in the cowel space. Well done. I'm going to think about this one when the temps get warmer.

 

The water/meth pump and nitrous controller never get wet in the cowl,mini designed a very good drain system for the cowl area .

The only way that a mini with a dos cai would hydrolock is if the car was submerged .

 

Well, after 4,000 miles of use my new CAI setup still rocks! I am heading to the track this weekend for a two day HPDE. Will report back on how the car performs and what the IA temps register during and after track sessions.

 

Looks like an ingenious intake mod! Good job!

 

 

Hey Gang! Back from two awsome days at the track driving in a HPDE school. The car ran really strong and made tons of boost, I saw steady 14-15 psi under WOT in fifth gear down the front stretch of VIR, topping out at over 100 mph, (114 on my fastest pass). The car held boost throughout the whole run and the throttle really felt responsive. Wish my tires had a little less sidwall flex to handle all the available power in the turns. Unfortunately, I was not able to monitor AI temps while on the track. My ScanGauge is mounted under the center console toggle bank and there was no way for me to take a glance in that direction while driving on the track. Heck, I barely got to peek at the tach!

Anyway, the intake still seems to be working flawlessly and with noticible gains on butt dyno, throttle and turbo response. Gas mileage is not very good under track conditions - I averaged 11.5 mpg for most of the runs, but was happy to see 37 mpg average for the return trip home last night!

 

Paleo,

The IA temp will climb quite a bit on the track sometimes to 25-30 degrees F above ambient, perhaps even more. The temp is measured after the IC so a better (bigger) IC can be important on the track.

Was the HPDE at VIR. S-driver and I am going in June for the 4.2 mile grand course. 2 hours a day for two days over the weekend of June 12-13.

 

Slinger - Yes I was at VIR. I love that place. Two days will wear you out there. I do have a larger IC (Forge) and it makes a huge difference right out of the box, really good investment for the MCS. I was under the impression that the IA temp on the Gen II MCS was taken at the MAF. I would like to see what is coming out of the IC if I could.

 

Two hours track a day for two days... Cannot wait. The most I have done in one day is 5 hours.

I have the Helix IC and the 25-30 degrees I mentioned is on cool down lap.

Take a look at part 5. It is after the IC.