So i started a new project for the hell of it, i wanted to see how hard it was working with Carbon Fiber, plus try to make my own ice box type setup.

Here's my current and original design:

https://acurazine.com/forums/3g-tl-performance-parts-modifications-112/blues-custom-type-s-intake-688562/

My goal with V2 was to make an intake box that didn't allow any hot air to get in. To get to where i am now, SUCKED. I basically spackled and bondo'd the hell out of a stock airbox to get it the shape and size i needed and then CF's the whole thing (which sucked due to all the curves and such i had to get it to adhere to). Overall it came out OK for my first ever try at CF or any sort of fiberglassing for that matter.

I have attempted a test fit and it looks like it will fit perfectly (thank god) but it need a lot of polishing, adding trim and making it look "pretty". Once that is done i'll install the whole thing and let you know my thoughts.

Here's what it looks like now, the setup will ultimately be just like V1, except it will be a perfect fit without any openings for air to get into. I will continue to use the stock tubing and the Apexi power intake filter.





(this is how it looks after a good wetsand, i still need to compound and polish it). Cool thing is it's pretty much featherweight! Well, that's the purpose of CF...haha

When it's all done, hopefully it will be fully functional and good looking. I will never attempt a project like this one again...took SO long and sliced the hell out of my hands, lol.

 

any plans to dyno and see if it actually produces gains?

 

looks good.. i wonder how fiberglassing an oem box would work... def weight savings but not sure how it works with heat...

 

Good job man! That's funny, because I dug my stock box out of storage to see if something similar could be done.

I was thinking if there was a way to replace the stock tubing; say cut from a AEM V2 to fit through the box. It would probably work if someone made a cone filter skinny enough to fit in the enclose stock box. I will poke around to see if this is possible.

I wish someone would get off their butts an make one like Comptech designs for the 2g. I would be all over it.

 

finished it up more or less tonight...

I had to drill some holes for the stock bolts and clips (this thing fits pretty damn well), i attempted to polish and wetsand the CF box...it came out ok, so i decided to clearcoat it...also came out ok. It's not as perfectly smooth as i might like, but it's good enough and I have had enough with this project!

Pic of it polished up some and clearcoated with the stock intake hose installed.


Inside of the airbox, Apexi Power filter. This was the only way i could install this thing but installing the intake tube and filter first, then laying it in the engine bay.


what's that peeking out?


Real nice and tight fitment around the intake hose...no hot air is getting in here!


Top down shot of the finished product.


how is it? no idea, i literally just finished up, i'm dead tired and it's pouring rain out. I imagine it will be just like my V1 except no hot engine bay air will get into the filter box... but i like the stock-ness of it and it's still using the great Apexi filter...it's gotta be win-win!

 

Not bad for your first try with carbon fiber. A lot better than mine would look I'm sure, haha. I'm curious to see if you see any actual gains out of it. The stock intake system on the TL-S is a pretty well engineered piece.

 

ok, just went out for a drive...feels very similar to my V1 setup, maybe a tad quieter and better response (although it could be all in my head). When i got back i popped the hood, of course the intake was warm/hot...not burning hot like the engine cover, but still fairly hot. But, the right side of the cover was actually pretty cool..which leads me to believe the following:

I'm a little apprehensive about cutting my cover apart, but similar to the Gruppe-M style, i think cool air may be forced through the battery cover and right in to the intake box if i decided to go this route.

decisions decisions...

 

that looks hot bro, good work. dont cut it! how much more air would it actually get?

 

i like it. Very nicely done [especially for your first attempt at CF]
How much did this revision cost you?

 

^ thanks! carbon was like 40 bucks on ebay (for about a square yard). the resin and hardner was like $60, and other little things like sandpaper i needed, spackle (for my bootleg mold) and other stuff -$25 - 30. Prob around $150 for all the supplies. I do have CF left and a ton of resin so some day i may attempt something else that is simple!

 

Looks good! looks oem


U can cut it at the edge, but then again..that air wouldnt be filtered. I would also get a throttle body spacer if u dont already have one..defintely need one of those if u plan on doing a SRI

 

^LOL nvm what i said about the air not filtering..trippin

 

^ lol. i dont think i want to cut it....i like the full cover too much!

 

just curious did you route air up using a velocity stack also?

 

looks good. very similar to 1g tsx's mugen intake that costs a fortune

 

Ok, i've been fussing around with this intake a bit more, just to make it as good as can be.

I made a custom heat shield to further block engine heat from the intake area...here's what it looks like now.







And here's my reasoning (should be pretty obvious, but i'll explain it):

Cooler air comes in through the channel in the battery cover to the intake area (also comes in through the front area near the drives headlight (there is a plastic duct that sends some air past the battery to the intake area) and through the stock intake/resonator tubing inside the fender area. From my image that i posted before, you can see the areas of the CF intake box that gets hot and areas which are cool after a half hour or so drive. By adding the heat shield, it almost encloses the whole intake area (when the hood is closed) away from the motor and the hot air. Cool air is allowed to come in and is recirculated within that little "box" with very little escaping. This keeps the intake box itself cooler and the air inside it cooler. Paired up with the Apexi Power filter, i think this is as good of a setup as possible for the TL.

Observations:
The box is much cooler than when i did not have the heat shield and overall the car seems not to have any heat-soak or lag that i started noticing with my V1 intake. I'm finally content with this setup, just thought i would share for any Do it yourselfers!

Hope you like it...

 

that looks nice

 

talk about true R&D! haha nice!

 

Why dont u try taking off the top right pannel so more cool air circulate from there. I bet that would help a bit.

Its like a little heater there

 

Nice work.

 

Very creative.

 

this is a proper SRI, that will show results

 

thanks!

After my ride into work today i popped the hood and felt the air box... seriously it was ice cold. It was a cool morning anyway (around 60 degrees) but the engine cover was still hot as hell. I'm really VERY pleased with this intake...it was worth the HOURS of work! Glad the project is finally done!

 

You should find a way to market this thing. It would definitely be a very high demand; you would make a killin!

 

Awesome job! Looks great and sounds like it works well. I'm waiting for your next project.

 

see now this is good you didnt do a hack job like some others i have seen A+

 

What did you use to make the heat shield?

 

honestly...and this is going to sound very bootlet but it worked great. i cut apart a blue office-style recycle bin so i could get a slight curve towards the top. i used high gloss vinyl to overlay it and turn it black, then used some weatherstripping that i had lying around for the top. I also put some door edge molding on the sides of it. came out looking perfect IMO though!

 

your right, with a little enginuity (and money) anyone can accomplish anything.. hahaha

 

Take it from a Carbon Fiber freak....well done!

 

 

That looks freakin sick man!

 

wow.

 

holy thread bump just to say 'wow'

 

def looks good P...

 

First off that is one sick air box/filter setup.

Quick question:
Would it be better to use some sort of straight pipe from the filter to the throttle body? i understand that the dryer hose constricts the airflow a bit. I dont think it would create a huge gain but you could paint the tube black and make it look more stream lined or even carbon fiber the tube.

Still its a killer lookin setup man. I would defenitly buy one if it was mass produced.

 

Nice build. Cant wait to see it on the dyno for results.

 

Clean!!

 

Very nice! That would be perfect for me.... All I want is a decent short ram intake and I haven't been able to find one. I don't want a cold air intake because of street flooding. My friend's 05 sucked up some water not too long ago just like a straw. Something like this would be nice to have!