High pressure intake

[Siestarider]

There is much posted about temperature and various intakes, but after using a manometer to test pressures at speed both inside engine bay and outside on body (data posted in aero and cooling thread) I theorized that one reason 2J intake makes power is its location inside cowl, which is a high pressure location.

Of course, stock intake is also in a high pressure location, inside nose cowl. I have a Mountune intake box, which has a lower hose that is supposed to be located in "cool" air behind fog light. When pressure tested, that location is negative, i.e. below atmospheric. Once I learned that, I blocked the lower opening and could find no difference in performance across datalogs before and after running stock turbo and Cobb S3.

My pressure testing indicated fog lights are also located in a high pressure location. I have only used them once, seldom get fog here, so I wondered, what if I took out the driver's side fog lamp and installed an intake hose from fog opening to the lower inlet in Mountune box?

Fog lamp removed, aluminum shrouding glued on, bug screen glued on from inside.

2.5" flex hose glued to flange, neoprene gasket cut to fit.

Other end of new intake hose attached to lower Mountune intake opening with zip ties over spare silicone connection.

Connected flange to rear fog light box with stock screws and some washers to hold it

Cowl ready to pop back in place.

All done.

Ok, ready for data? Me too. Bad news is I changed too many variables at one time to have decent data. Mounted Cyborg while I was in there.
But theory is with two high pressure intake points, compressor should not have to work as hard, ie this intake should not pull a vacuum at speed. I can say its quiet, and the Cyborg runs quieter on Cobb S3 than stock turbo did. Drone on customized 3" MBRP is gone. I was waiting to put a new exhaust on until Cyborg was mounted and I could get some logs run, now maybe I keep it.

Summary, cold air intake is a bit of misnomer down here in Fla, there is no cold air outside. But what there is, this mod has. According to pressure mapping, it should be a good mod. Have to start tuning to see what it can really do, and I can always block the lower intake later on and report what difference if any this makes.

 

[me32]

Very interesting what you have going on there. Let us know how it works out.

 

[OCS12]

Nicely done sir! I like your style.

 

[Siestarider]

Thanks gents. Looks like I will have to tune it to higher hp, then block intakes in turn to really find out what it does. Tuners are not beating doors down to have a chance at Cyborg, I have ATR but fully appreciate its complexity having played with it some, this is not the time for amateur hour. Need a pro who is really interested in this platform. Any leads appreciated.

 

[M-Sport fan]

COOL!

You already had the brake ducts in the strakes before you did this, or you did that at the same time as well??

 

[Bluedrank]

Looks similar to the sektune intake from years ago. http://www.fiestastforum.com/forum/threads/399-Sektune-Cold-Air-Intake/page2

I'd be very interested in seeing the data with the hose working compared to it blocked off. Being in Florida also, my big concern with doing something like this was sucking water in through the lower hose.

 

[BiigMe]

Glad you made your own thread! Even if the data will be skewed from your initial setup I'm still interested to see how that airbox works out for you. Hopefully the Ram air scoop from VelossaTech isn't too far out for me because I'd love to compare it to your setup.

 

[Siestarider]

I thought about the water intake issue, but it becomes a non-issue when you think it over carefully. As long as air box has two inlets, the lower inlet cannot generate any vacuum to speak of. Certainly not nearly enough to pull water two feet up.

I like the Velossa approach, but already had this air box, rather than delete it tried to find a way to improve it. And yes, I started a new thread so I would not forget to collect data and report it. Aero mods and cooling is not done either, just have to get coils in and ride height set (little lower) before resuming work on that topic.

Have to say, drone being (almost) completely gone and turbo so eager to run higher r's is great fun. Cobb S3 works better than I would have thought with Cyborg. Feels a lot livelier, in part because I don't short shift to avoid drone on street. Since I have to collect some logs to start tuning anyway, I will get some soon. Shame to make so many changes at one time, cannot tease out the incremental differences. But economy of my own time forced me to do it all at once. Plus I had a track day scheduled for Tuesday, which I had to postpone until August, did not have enough confidence in my own work to go straight to track without logging first.

I love my car. More than ever. Heard about some fool who married his car, not that kind of love.

 

[frankiefiesta]

Thanks gents. Looks like I will have to tune it to higher hp, then block intakes in turn to really find out what it does. Tuners are not beating doors down to have a chance at Cyborg, I have ATR but fully appreciate its complexity having played with it some, this is not the time for amateur hour. Need a pro who is really interested in this platform. Any leads appreciated.

Always like reading your posts! Another great read.

I suggest [MENTION=1098]DHM[/MENTION] .They really took an interest in my cyborg build and I don't regret the decision at all.

 

[frankiefiesta]

Thanks gents. Looks like I will have to tune it to higher hp, then block intakes in turn to really find out what it does. Tuners are not beating doors down to have a chance at Cyborg, I have ATR but fully appreciate its complexity having played with it some, this is not the time for amateur hour. Need a pro who is really interested in this platform. Any leads appreciated.

Always like reading your posts! Another great read.

I suggest [MENTION=1098]DHM[/MENTION] .They really took an interest in my cyborg build and I don't regret the decision at all.

 

[Siestarider]

COOL!

You already had the brake ducts in the strakes before you did this, or you did that at the same time as well??

There is a thread somewhere in Brakes section on this, I made the vents first, then had a hell of a time figuring out how to plumb the lines. CMB ducts solved the problem, 2" works great, I was trying 3" and it just would not fit.

 

[VelossaTech]

awesome stuff, keep it going.

 

[Siestarider]

Little hint of data. I ran my first full throttle logs on Cyborg yesterday on base tune. The only thing that really caught my attention was CAT vs RPM. Ambient temp 88F. Heat shield off at moment for tuning WG as needed.

At 100% throttle, 2500 rpm, CAT 97.7F; dropped steadily to 95.2 F at 4200 rpm; back up to 97.7 by 5300; 102.6 at 6500; maxed at 103.8 F 1/2 sec after lift off at 6700 rpm; 101.5 within 2 sec after liftoff, log ended.

Second log, 100% throttle 2500 CAT 96.3; down to 95.0 at 4200; 103.1 at 6500, didn't log any coast down on that one.

Standard Cobb I/C, compared to stock logs at relatively high ambient temps my starting CAT is higher without heat shield on, but drop in CAT larger between 2500 and 4200 rpm now than on stock intake before I closed the lower Mountune opening.

A better test will be forthcoming when I have Cyborg done on 93 and can log with and without the extra cooling inlet. And remounted heat shield.

 

[Bluedrank]

This is such an awesome project. I might just do this one day when I get brave enough. I sourced some parts from aliexpress for pretty cheap, if I decided to give it a go.

 

[M-Sport fan]

Which heat shield above?^^^

 

[Siestarider]

Which heat shield above?^^^

I left manifold/turbo heat shield off after Cyborg install just in case I need to adjust WG during tuning. Manifold is heat wrapped, but I also left turbo blanket off for now. I imagine heat shield being off is bad for intake air temp and thus CAT. Last time I left it off, probably after DP install, I was getting at least 5 degrees higher IAT at speed, so put it back on.

 

[Siestarider]

Update: Removed cyborg for diagnosis of boost loss, put stock turbo back on, Cobb S3 map. I did keep ported exhaust manifold on, just to see if I could find a difference between it and prior stock runs. Ran two logs with fog air blocked and two with it open, same stretch of road I always test on, 84 F ambient, pretty windy so averaged VD results.

Oddly, downwind results higher HP than upwind for both runs. Guess 10-15 mph headwind vs tailwind is enough to overcome any intake air improvement. And a good reminder VD does not compensate for wind.

I interpret these results to indicate 3-4 whp improvement with additional fog light intake. Red is fog intake blocked running upwind, blue fog intake blocked running downwind, green fog open upwind, orange fog open downwind.

On the question of whether ported manifold makes any difference (note turbo not matched to exhaust port, so this would only test upstream runners) I checked a bunch of data collected with stock turbo/manifold, best I can tell I have never logged over 203 whp with my car. So I am guessing a whp or two attributable to manifold porting.

So, consistent results in the right direction, but not big results. On the other hand, cheap hp considering I was going to remove the Mountune intake because it did not make hp, and similar to 2J cowl results reported by others. And silent.

 

[Bluedrank]

Hey I was revisiting this thread to check up on your progress.

After running with the foglight vent for a few months, how are you enjoying it? Have you noticed any water getting inside due to the Florida rains? I've noticed small amounts of water making it inside the intake tube and past the green filter from my Velossa snorkel, but I assume small amounts would be acceptable due to the fact that they'd evaporate from the heat? Additionally, it looks like you create a way to block the port. What did you come up with to do that?

I'm really considering taking this on as a project in the next few months because it sounds fun and unique.

 

[OCS12]

Hey I was revisiting this thread to check up on your progress.

After running with the foglight vent for a few months, how are you enjoying it? Have you noticed any water getting inside due to the Florida rains? I've noticed small amounts of water making it inside the intake tube and past the green filter from my Velossa snorkel, but I assume small amounts would be acceptable due to the fact that they'd evaporate from the heat? Additionally, it looks like you create a way to block the port. What did you come up with to do that?

I'm really considering taking this on as a project in the next few months because it sounds fun and unique.

I copied Siestarider's idea and had no issues, including when I ended up with the fog light vent submerged during a nasty storm. The change of intake sound scared the crap out of me, but when I got home and opened up the air box the filter was dry.

I've gone back to the Mountune style location after adding the Velossatech, but never had issues.

 

[Siestarider]

I have been running this mod for couple months now, must report I just lunched a second Cyborg compressor. Although I can think of nothing this mod should do to an intake that 2J does not also do, better to report facts and see where dust settles. This is the only unique mod I have that could affect compressor. While I doubt it does, maybe I am wrong.