I finally got around to installing an Amsoil air filter in my '06 JCW cabriolet and while the air box/flapper assy was on my workbench, I was pondering whether or not to remove or disable the flap. Then it occurred to me that I might have the best of both worlds if I got creative. In short, what I did was to leave the entire mechanism intact and functional but added a small wire attached to the flap whereby I could pull up on it to open the flap and latch and hold it in the open position. I'll post some pix that should be pretty self explanatory. I also cut apart the old stock filter and attached part of it to the new filter with 3M ultra high bond double sided tape (3 mil thick) so that the stock clamp could hold the Amsoil filter in place just like the stock setup.

What I did was locate a place where I could make a small hole just to the side of the vacuum diaphragm that operates the flap where I could run a small SS wire down to the bottom edge of the flap. I drilled a hole near the edge of the flap and put a small glove on the edge of the flap so I could have the wire loop around and through he hole and not keep the flap opened when I wasn't pulling up on the wire.

These pix show the wire and if you zoom in on a couple you'll see how and where I attached it.







These pix show the wire and if you zoom in on a couple you'll see how and where I attached it.

 

I then created something to hook the wire on that would be easy to get at when I wanted to without removing anything or opening anything up. The result was I can pull up on the wire and hook it on the Delrin piece I fabbed so that the flap is open all the time. And when I don't want the little bit of extra noise, I unhook it and the flap works as normal with the wire simply moving up and down with the flap.

 

Finally, here's what I did to hold the Amsoil in place better so I'm not entirely depending upon the clamp.

 

As it turns out, with the flap open, it's really not all the much noisier, though maybe because I've got a convertible, I don't notice it as much. So far I've left it held open but when the wife and I head out for a road trip, I'll likely unhook it and let it function as it was originally designed.

 

That's a really elegant mod. Well done!

 

Thanks!

 

We remove these flaps all the time. It's actually much easier than adding the wire like that. If you just take the 4 phillips screws off the back the whole thing will come off and you can just slide the flap off the rod that moves it. Then just bolt it back on. The rod will still move and function, but because the flap is gone it will be open all the time.

 

Oh, I understand all that. If I'd decided to simply remove it, I'd have been in and out of the garage in 10 minutes. However, not having ever heard my Mini with the flap open all the time, and being a compulsive tinkerer, I decided to do the flap mod in a manner that would not require that I have to tear things apart to reinstall it should I not like the results. Now all I have to do is pop the hood open and either hook or unhook the wire to suit my mood.

 

I still think your solution is really elegant even if Mr Way doesn't.