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Standard airbox flow improvement

Discussion in 'Modifications' started by jcuyckens, Sep 30, 2016.

  1. jcuyckens

    jcuyckens Copenworld Member

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    Volvo XC60 2015
    Toyota Corolla 2004
    Rover 45 V6 2005
    Daihatso Copen 2006
    BMW R850RT & R850R
    Yamaha GTS1000 1993
    I used the discharge side of a second airbox and combined this with the suction side. Resulting in a bigger volume and in and outlet equal ( bigger) diameter. See pictures. Engine rpm acceleration and reaction speed improved.
     

    Attached Files:

    MultiplexMan likes this.
  2. Salieri

    Salieri Copenworld Veteran

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    Can you explain a little bit more what you did exactly?
     
  3. jcuyckens

    jcuyckens Copenworld Member

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    BMW R850RT & R850R
    Yamaha GTS1000 1993
    I bought a second airbox and took the half, going to the air intake. Then cut off the flange and dit the same to my half, going to the fresh air intake. This flange i connected to the first part. Resulting an bigger airbox with less air restriction and still looking original.
     
  4. Salieri

    Salieri Copenworld Veteran

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    But what are the screws for? And what part number has the second airbox? Is it also a daihatsu one and does the air filter fit?
     
  5. MultiplexMan

    MultiplexMan Copenworld Regular

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    That's a novel way to increase the airbox size whilst keeping the original air filter.
    Great idea salvaging the flange from the original suction side. Did you silicone/PU seal the cut discharge section to the reclaimed flange before screwing them together?
     
  6. jcuyckens

    jcuyckens Copenworld Member

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    BMW R850RT & R850R
    Yamaha GTS1000 1993
    It was a tight fitting, but i added some Tec7 to be sure there is no air leak. The bolts keep the overlapped peaces together. It really makes the engine spooling up faster.
     
  7. jude

    jude Copenworld Newbie

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    Interesting idea :)
     
  8. Khalid

    Khalid Copenworld Newbie

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    Has anyone tried this?
    I've always found the throttle body intake pipe odd on these because it looks squashed and restricted.
     
  9. Salieri

    Salieri Copenworld Veteran

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    I would try it if jcuyckens would make a detailed guide. I do not understand how this is supposed to work
     
  10. jcuyckens

    jcuyckens Copenworld Member

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    There is also a possibility to exchange the throttle body intake pipe by a Cobra head silicon intake piece.
    But I could not find one with this small diameter.
    I've used a highly modified mercedes SLK intake pipe, but I've a bigger throttle body then yours due to the 1.5 engine.
    The YRV turbo intake piece will fit, but is impossible to find. (height is ok??)
    I've added some extra pictures.
     

    Attached Files:

    Salieri likes this.
  11. Khalid

    Khalid Copenworld Newbie

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    Wow! lots of good ideas here. A YRV Turbo throttle body intake pipe has a great big opening and doesn't look as restricting. A good fitting silicone hose could do the job but I would like to try and make it look as original as possible.

    Thank you for sharing more pictures of the air box. It's a lot more clearer to me what you did. It's certainly something I want to try do if it makes a noticeable difference.
     
  12. Salieri

    Salieri Copenworld Veteran

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    Thanks again jcuyckens for the explanations, I have attempted to manufacture an intake using the following:

    53mm plastic gutter pipe and a 45° angle = 6€
    54mm silicone 90° elbow, which i cut down to save height. = 14,50€
    Cheap JOM Podfilter = 8,99€
    2x Hose clamps = 2€

    Total: 31,49€

    I have the impression that the engine needs a little more time to get going, but when it starts going, it is noticably faster. I have not made any tests yet, as I only wanted to see if it works, maybe use it for track days. You should not use this as a permanent replacement
    Soundwise, its pretty good!

    air intake.JPG
     
  13. jcuyckens

    jcuyckens Copenworld Member

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    Yamaha GTS1000 1993
    It is good to experiment! I see one downside in this setup; the air inlet is located behind the radiator and therefore sucking in hot air. You could prolong this pipe to the bottom part of the radiator.
     
  14. Salieri

    Salieri Copenworld Veteran

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    Yes, I have thought about that, it should be easily doable with additional piping. but you would have to maufacture some kind of holding mechanism so it does not move around
     
  15. marnob

    marnob Copenworld Regular

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    Have you seen the nice Stainless steel air cleaner set up which still uses the same standard air cleaner element?
    Very nice looking but instead of shelling out a heap of money for that I just copied the hole configuration as best I could from a photo.
    Drill a heap of holes in a grid similar to the Stainless one. Cut off the stupidly small induction plastic piece as close to the box as possible. You really need to cut it off to get the Air Box out as I couldn't find another way. Didn't matter as I wasn't going to use it.
    You need to chisel out the bits of plastic left over from the drilling.
    I also ran some sandpaper down the inside as well.
    Don't drill holes in the front of course as you don't want dirt and water getting inside. Just keep it the same as the Stainless one, which has heaps of holes.
    Fitted a nice new D-Sport Air Cleaner Element, which has much larger intake opening and what a huge difference.
    Sounds like its got a blow off valve on it now.
    Instant Pod type Air Cleaner but totally standard look from the front.
    Price, your time.. Copen Air Box.jpg
     
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  16. Salieri

    Salieri Copenworld Veteran

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    Nice, unfortunately this does not work on the 1.3L model :D
     
  17. jcuyckens

    jcuyckens Copenworld Member

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    Yamaha GTS1000 1993
    Hello, I am not familiar with the turbo engines, but sucking in hot air is not benefitial. The intake piece diameter is important and also the location of the air inlet.
     
  18. marnob

    marnob Copenworld Regular

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    The size of that intake is so small it doesn't allow enough air flow for the engine to breathe?
    I just copied what one of the well known Japanese manufacturers of Copen Performance parts had already made?
    I posted it on here as it doesn't cost anything but your time to copy it and benefit from the engine performing better?
    Simple cheap Mod!
    I can tell you, that this makes a huge difference to the power of the car so the heat thing your talking about is irrelevant. Getting cooler air is always tricky.
    After a lot of research it doesn't seem to make much difference to the HP of the car in the end.
    Airflow is far more important and the POD's allow that more so than perhaps the temp of the air.
     
    Last edited: Mar 6, 2017
  19. Krusty2fast4u

    Krusty2fast4u Copenworld Member

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    Could I put a cone filter in as a replacement instead of modifying the existing box? If not why please! Thank you
     
  20. marnob

    marnob Copenworld Regular

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    As Salieri said, he has the 1.3 Copen.
    Mine is the Turbo Copen model so the Air Intakes are quite different?
    I could have chose to put a POD filter on but I wanted to try and keep it standard looking.
    Plus I felt the POD has the tendency to easily get water and dirt into it.
    You can't put it straight on the Turbo one without some mods.
    Probably the same with the 1.3 too?
     

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