[peterparker]

Hey Guys,

So I have an itch for a new project, a Single Fat Filter CF Intake.

This will mimic the UR and Strett intake. Will be a short ram for ease of installation and maintenance. & CF due to less heat soak and awesomeness. Also I'm thinking of creating a simple CF heat shield with a air inlet from the factory scoops.

The Power Steering will be relocated to either the near the fire wall (Location of the 328i PS) or the near the bumper support (Look at the Injen Intake setup for reference.)

2.25" Inlets that merge into a 4" pipe. With options of a few K&N filters starting at 27.99.
http://www.knfilters.com/search/prod...od=RG-1001WT-L
http://www.knfilters.com/search/prod...x?prod=RF-1015
http://www.knfilters.com/search/prod...rod=RU-5171HBK

Going to make this clear the stock DV's (Because that's what I have) and trying to assume/guess clearance for VRSF's Charge pipe with a Tial bov.

Construction is going to consist of 4 thick layer CF (2x2 6k twill + Sleeve), west systems epoxy resin, vacuumed.

Since I'm going to create a mold, I might as well make more and sell them. Since there's like no CF intakes available for our cars under $1,000. So let me know if you're interested!

Any input and suggestions would be greatly appreciated.

Here's a quick sketch:


Update - Finished wrapping the Mold with casting tape.
4/30






I still have to make a few more adjustments to this mold because the inlet pipes are way out of spec. Because I kinda got happy with the casting tape.

Not to mention the actual CF will add about 6mm(.25in) in the total Diameter.

Update - Tweaking
5/2

Got the mold cut in half, Tweaked the mockup, test fitted, cut off the ends of the mold and re-casted the ends.

Next step: Lay the inside of the half's with fiberglass for reinforcement then join the 2 half's with a layer of fiber glass on the outside. Then sand and smooth away everything.
Finally I should be ready to create a fiberglass prototype.

Notes: Filter placement is really right. But I designed it so there's some room for play/movement. There's also a 5" tall filter I may try instead of this 7".

[CHECKERED]

Will need to see prototype first.
and I would strongly prefer a CAI or some type of ram air (from factory scoops) system

[Myrder]

Look at SLP blackwing
http://www.summitracing.com/parts/sle-21035b/overview/
I wanted to do something fun intake wise, but for the life of me could not find the dimensions of this filter!

[peterparker]

Originally Posted by CHECKERED

Will need to see prototype first.
and I would strongly prefer a CAI or some type of ram air (from factory scoops) system

Of course! Imma create one for my self first! Tweak tweak tweak till perfection! Then I can start slaving away!

Originally Posted by Myrder

Look at SLP blackwing
http://www.summitracing.com/parts/sle-21035b/overview/
I wanted to do something fun intake wise, but for the life of me could not find the dimensions of this filter!

Interesting! That's a cheap filter. doing some quick photoshopping with a ruler. Here's 2 possible measurements.

[N54POWR]

I'm always interested in cool diys. Keep us updated!

[Myrder]

Originally Posted by ivtecc

Interesting! That's a cheap filter. doing some quick photoshopping with a ruler. Here's 2 possible measurements.

I'm almost ashamed I didn't think of that. Nice job. I was going to order one for tests but never got around to it. I did call SLP and they were to lazy to get one and put a ruler to it....

edit: looking at the screw clamp I think the 3" inlet is more probable.

[BAL278]

Keep us posted! I'd love to see this come to fruition

[Tiago@VRSF]

Looks good!

My only suggestion is that you reinforce the filter inlet areas, every C/F intake I've seen generally fails at the main point of pressure from the clamps.

[_ink]

Originally Posted by Tiago@VRSF

Looks good!

My only suggestion is that you reinforce the filter inlet areas, every C/F intake I've seen generally fails at the main point of pressure from the clamps.

Agreed!!

Would prefer it in hard AFE like plastic, and then wrapped in CF.

[peterparker]

Originally Posted by Myrder

I'm almost ashamed I didn't think of that. Nice job. I was going to order one for tests but never got around to it. I did call SLP and they were to lazy to get one and put a ruler to it....

edit: looking at the screw clamp I think the 3" inlet is more probable.

Thanks! And let me know about that intake, I may have to downsize to 3.5 or 3 due to space constraints.

Originally Posted by BAL278

Keep us posted! I'd love to see this come to fruition

Will do!

Originally Posted by Tiago@VRSF

Looks good!

My only suggestion is that you reinforce the filter inlet areas, every C/F intake I've seen generally fails at the main point of pressure from the clamps.

Ahh ic! Thanks for the heads up, I'll def take that into consideration.

I was also thinking of cutting this intake in half, right after the merge. And slipping a v clamp flanges right over on both half's. Using epoxy to keep it in place.
Just for easier access to the charge pipe, easier installation and filter replacement. Since the preferred filter that I want to use is HUGE.

Whats your thoughts on that?

Originally Posted by ChefHaze

I'm always interested in cool diys. Keep us updated!

Will do!!

Originally Posted by _ink

Agreed!!

Would prefer it in hard AFE like plastic, and then wrapped in CF.

I have no access to hard plastics! Nor a welder and/or anything fancy.. I'm just building this from my basement and garage. =\

Maybe down the road, I'll find a company that can reproduce this in plastic. Then yes!

Originally Posted by CHECKERED

I would strongly prefer a CAI or some type of ram air (from factory scoops) system

The front intake air ducts will be rerouted into the heat shield; into the intake area. Does that Count as a ram air intake? Or does it have to be completely sealed off, like in a sealed box?

[nikitino25]

Why don't you make something more along the lines of the Dinan or Mr5 type intake.....this design gives you two ports for incoming cool air, the same stock path and also the lower filter in the bumper area. I'm in process of making a Mr5 intake myself but using a 2.5" tube for the lower intake because of the structural bar in the way that I think only the e92 coupe has. It's slightly ghetto and I'd love to have some kind of plastic or carbon fiber tube like the Dinan but not willing to spend $1300 on an intake....

[Island Road]

I would be in but I would want a direct CIA going straight to the FOG Light Delete mode used as a CIA Intake with K&N Apollo intake.

I have all the parts plus two different intakes one Applo and some other one that is larger but also enclosed just a matter of making the pipping now.

[Zebra99]

If you could make a Dinan replica in CF that would be awesome...CAI or nothing!

[uberbeast21]

if you could make something like the stett intake but in carbon fiber that would be awesome, a little tricky, but awesome

[AYEDEE]

Wow big task ahead of ya!

[peterparker]

The mock up piping is almost complete, Just waiting for the filter to come in for final fitment. Hopefully I can get the Fiberglass prototype done this weekend and then the testing starts! I'll post pics once that happens.

Changes-
There's no way the K&N RU-5171HBK dry filter would fit. And all other filters are oiled.
So I went with a smaller filter made from AFE. Looks exactly the same as the Takada filters.

http://www.autoanything.com/air-filt...cement-filters

21-40011
6" Base, 4.75 Top, 7" Height.

Also the intake pipe will be reduced from the original 4" to 3.25"/3/50" because there's no way I can fit a 4" intake in the space given.

Originally Posted by AYEDEE

Wow big task ahead of ya!

You have no idea! Just making the mockup is a PITA!

Originally Posted by uberbeast21

if you could make something like the stett intake but in carbon fiber that would be awesome, a little tricky, but awesome

Basically this is almost a strett replica... Sorry Strett!

Originally Posted by Zebra99

If you could make a Dinan replica in CF that would be awesome...CAI or nothing!

Thats a lot of work! Perhaps in the future...

But I may make a CAI variant soon after. And I do want to make this intake modular with v band clamps. Just so I can swap out different filters / intake styles easier.

Originally Posted by Island Road

I would be in but I would want a direct CIA going straight to the FOG Light Delete mode used as a CIA Intake with K&N Apollo intake.

I have all the parts plus two different intakes one Applo and some other one that is larger but also enclosed just a matter of making the pipping now.

Looks good man! Keep me updated.

Originally Posted by nikitino25

Why don't you make something more along the lines of the Dinan or Mr5 type intake.....this design gives you two ports for incoming cool air, the same stock path and also the lower filter in the bumper area. I'm in process of making a Mr5 intake myself but using a 2.5" tube for the lower intake because of the structural bar in the way that I think only the e92 coupe has. It's slightly ghetto and I'd love to have some kind of plastic or carbon fiber tube like the Dinan but not willing to spend $1300 on an intake....

I may look into a MR5 style intake in the future one. And I agree $1300 on an intake is nuts!

[peterparker]

Updated!

Fitment is good once I removed the AC Bracket/Brake Booster bracket. I'll have to create a new bracket for that and the Power Steering. Also Clears the Stock DV.

But the real question is, Will I clear VRSF's CP with a Tial? Looks a little tight.

[uberbeast21]

Originally Posted by ivtecc

Updated!

Fitment is good once I removed the AC Bracket/Brake Booster bracket. I'll have to create a new bracket for that and the Power Steering. Also Clears the Stock DV.

But the real question is, Will I clear VRSF's CP with a Tial? Looks a little tight.

Any update?

[LQQKOUT]

Good work! Keep us posted on the progress.

[Island Road]

lol ugg nobody else seems any resemblance to the human anatomy here??





On a completely different note not related to the male genitalia 666 fabrication already did something like this, and is useless you make it a CIA going all the way down to the fog light no different than any other intake.

[peterparker]

Originally Posted by uberbeast21

Any update?

Not anything major, Just some more tweaking and modding. I also decided to downgrade to a smaller filter. 3.5in and an inch shorter for clearance. I still have to sand and bondo down the entire mold this weekend. Not really looking forward to this because working with fiberglass sucks! Even with a full protective suit.

Then finally CF process can start.

Originally Posted by LQQKOUT

Good work! Keep us posted on the progress.

Thanks and I will do!

Originally Posted by Island Road

lol ugg nobody else seems any resemblance to the human anatomy here??

On a completely different note not related to the male genitalia 666 fabrication already did something like this, and is useless you make it a CIA going all the way down to the fog light no different than any other intake.

Ahh ic, Thanks for letting me know. I'll consider making a CAI version in the future.

But I will really consider that Power Steering Mounting option.

Originally Posted by Island Road

On a completely different note not related to the male genitalia 666 fabrication already did something like this, and is useless you make it a CIA going all the way down to the fog light no different than any other intake.

Word, Ultimate Racing makes one like that:
http://www.ultimate-racing.com/xcart...7&bestseller=Y

Looks great, but too rich for my blood.