Custom R36 Cold Air RAM intake - Almost $0 DIY or small fee to get it done

[Elmura]

Hi guys,
Been a while since I updated this thread. I'm still using my "Elmura Cold Air Ram Mod" but now on my CC. The buyer of the R36 was keen to keep it on so I had to make a new one for the CC.

For the CC, other improvements included cutting out the "comb" plastic filter that sits just behind the grille. This required unscrewing the cover that sits between the radiator and grille and removing this long plastic piece (see pic). I then cut off the vertical pieces of plastic "comb" filter.


The idea behind this is to minimise obstruction (and thus pressure loss) for a superior RAM effect at speed. I also sealed up the gaps that adjoin the back of the grille with the intake scoop using strong tape that has held up thus far for almost 1.5 years.
There's a K&N panel filter in the air box that gets cleaned every 20,000kms

I siliconed sealed holes at the bottom the airbox to prevent hot air being pulled through.

I applied fibreglass heat wrap to barrier the airbox from the oil cooler & insulated the oil cooler pipes to reduce heat transfer to the airbox. Further, I heat wrapped the exhaust in the engine bay (a major task that I don't recommend) to minimise heating of the intake manifold. I also fitted a reflective blanket over the intake manifold portion sitting behind the radiator as I found this to be a massive source of heat.

#xR360As for the Forge intake, not only is it quite pricey, it's not designed to fit the CC or R36 engine bay. Also, the air box is quite small so I calculated that it would not flow as well as an optimised factory system.

However, I have started prototyping a similar version designed to fit the CC & R36 with larger ducts, straighter air flow, a much larger air box and very large pod filter. Early experiments with unsealed approach (sucking engine bay air) had performance loss in most street scenarios - but an improved highway speed performance. The problem is getting the air scoop above the radiator to connect with the rest of the system.
I had bell mouths fitted for smooth air transition and heatshield wrap around the "box". I tried aluminium piping & silicone. I haven't had time to complete this design though as I've been designing and owner building a house which takes up all of my time.

Off thread topic - I also ditched the centre "suitcase" muffler and fitted a customised exhaust bypass valve (2nd version of this experiment). With this open and at RPM >2500, all sonic hell breaks loose and it sounds wicked. I've been told it sounds like a V8 Supercar, a Lamborghini, and "insane". At low RPM it's way too loud & droney so I keep it closed except when I'm rolling up to lights. I wanted to automate it but it's a hassle so I keep the little remote at hand.

PS - In case your thinking I've completely lost it, I do have a Mechanical Engineering & Electronics Engineering background.