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My home-made ram-air intake (work in progress)
Hi all,
I just wanted to share the process of the design and build of a ram-air intake for my twincharged Beetle 1.4TSI(118kw).
I deciced to go for a software-development-like process:
I started out with
Step 1: Requirements.
From important to less important:
Step 2a: Design ideas
I was walking around with various ideas, since I've got some different filters here that I can use. Should I go for a big one (1, a big K&N filter), a small one with flow-enhancements(2, an Apexi filter...or 3, the same filter but with a tip a the front), or what? Some experts helped me out here, and I came to the conclusion to pick the bigger one.
Step 2b: Functional design
So I made a choice: go for the big one... but what would I need...? So I made this "sketch" in the most epic design tool ever given to man: MS Paint:
What is what?
Black: OEM setup, this will stay Original
Green: Silicone coupler, from 3" diameter to stock factory diameter.
Light grey: Aluminium elbow.
Dark red: K&N Filter, 9.25" x 5.91" x 5.91", 3" diameter connector
Purple: Inner part of the airbox, made from a protein cannister. It has a lid which can be opened/closed, which makes it easier to reach the filter in case I need to replace or clean it. The can is wrapped in heat-reflective alu-tape.
Dark grey: aluminium outside of the airbox, made from a cylindrical shaped object. Between the two layers of the airbox, there's isolation foam.
Blue: Silicone hose.
Yellow: Hose-connector, mounted onto the lid of the plastic can.
Red: Forge air-intake trumpet I still had lying around.
Here's the Protein-can...first I was thinking about using the Siemens-Porsche Coffeecans in the back as airbox, so I can say: I've got Porsche parts in my Beetle
Step 3: Measuring, technical design and prototyping
Not much to say about this step... I did a lot of measuring inside the engine bay to see what would fit. Then I did a lot of test-fitting with various aluminium cans, including a Warsteiner beer can. In the mean time, I occupied the car with a temporary "hot air intake" setup, like this:
In the end, the following turned out to be the best, using an aluminium trash can (the lid is not on yet, still have to drill a hole in it!). It's a perfect fit!
Step 4: Implementation
Now all I have to do, is drill a hole in the lid of the garbage can, attach it to the front, put all the parts together, and she's done! This will happen this weekend.
Step 5: Testing
not there yet!
More to come!
I just wanted to share the process of the design and build of a ram-air intake for my twincharged Beetle 1.4TSI(118kw).
I deciced to go for a software-development-like process:
I started out with
Step 1: Requirements.
From important to less important:
- Closed intake, connected to bumper
- Isolated airbox to prevent air inside from heating up
- Costs less than $100. Possibly even less
- Try to make use of stuff already available in my garage.
- Good looks
Step 2a: Design ideas
I was walking around with various ideas, since I've got some different filters here that I can use. Should I go for a big one (1, a big K&N filter), a small one with flow-enhancements(2, an Apexi filter...or 3, the same filter but with a tip a the front), or what? Some experts helped me out here, and I came to the conclusion to pick the bigger one.
Step 2b: Functional design
So I made a choice: go for the big one... but what would I need...? So I made this "sketch" in the most epic design tool ever given to man: MS Paint:
What is what?
Black: OEM setup, this will stay Original
Green: Silicone coupler, from 3" diameter to stock factory diameter.
Light grey: Aluminium elbow.
Dark red: K&N Filter, 9.25" x 5.91" x 5.91", 3" diameter connector
Purple: Inner part of the airbox, made from a protein cannister. It has a lid which can be opened/closed, which makes it easier to reach the filter in case I need to replace or clean it. The can is wrapped in heat-reflective alu-tape.
Dark grey: aluminium outside of the airbox, made from a cylindrical shaped object. Between the two layers of the airbox, there's isolation foam.
Blue: Silicone hose.
Yellow: Hose-connector, mounted onto the lid of the plastic can.
Red: Forge air-intake trumpet I still had lying around.
Here's the Protein-can...first I was thinking about using the Siemens-Porsche Coffeecans in the back as airbox, so I can say: I've got Porsche parts in my Beetle
Step 3: Measuring, technical design and prototyping
Not much to say about this step... I did a lot of measuring inside the engine bay to see what would fit. Then I did a lot of test-fitting with various aluminium cans, including a Warsteiner beer can. In the mean time, I occupied the car with a temporary "hot air intake" setup, like this:
In the end, the following turned out to be the best, using an aluminium trash can (the lid is not on yet, still have to drill a hole in it!). It's a perfect fit!
Step 4: Implementation
Now all I have to do, is drill a hole in the lid of the garbage can, attach it to the front, put all the parts together, and she's done! This will happen this weekend.
Step 5: Testing
not there yet!
More to come!
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