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.

[dvkent]

Wow. I have also deleted centre muffler. Roughly what cost for the exhaust bypass valve set up?

Sent from my E6653 using Tapatalk

[ZR36]

I would have to say that VW would have a team of engineers and designed the intake that way for a reason, and performed test after test after test on such design.
If such a simple change would be a significant cost/performance/efficiency trade off then VW would have made the mod themselves as standard. You wouldnt get increase performance AND efficiency without affecting something else such as engine life.

To make the air flow more "laminar" a cross sectional grid would not do alot. Especially being so far way from the value intake, buy the time its gets there its most likely turbulent again. You would need the addition of a thicker guide such as a series of straws that go as close to the ignition point as possible.

[Mysticality]

I would have to say that VW would have a team of engineers and designed the intake that way for a reason, and performed test after test after test on such design.
If such a simple change would be a significant cost/performance/efficiency trade off then VW would have made the mod themselves as standard. You wouldnt get increase performance AND efficiency without affecting something else such as engine life.

To make the air flow more "laminar" a cross sectional grid would not do alot. Especially being so far way from the value intake, buy the time its gets there its most likely turbulent again. You would need the addition of a thicker guide such as a series of straws that go as close to the ignition point as possible.

Volkswagen has done hours and hours and hours of testing on each one of the components in our cars; yet we still modify them.
If everyone believed the engineers did the best they could for everything then there would be no aftermarket parts business at all; no forums... etc, etc.

[Greg Roles]

I would have to say that VW would have a team of engineers and designed the intake that way for a reason, and performed test after test after test on such design.
If such a simple change would be a significant cost/performance/efficiency trade off then VW would have made the mod themselves as standard. You wouldnt get increase performance AND efficiency without affecting something else such as engine life.

To make the air flow more "laminar" a cross sectional grid would not do alot. Especially being so far way from the value intake, buy the time its gets there its most likely turbulent again. You would need the addition of a thicker guide such as a series of straws that go as close to the ignition point as possible.

They do indeed.

Then the emission team, the sound level police, and the bean counters all come in and make a mess of it. The typical intake is designed to flow enough air for normal use, be very quiet, and be cheap as possible and uniform across as many models as possible. It's a long way from optimal, and anyway, why not have a crack and do a bit of tinkering? The V6 would be an awesome motor to get more induction and exhaust noise out of, you should see how similar DIY mods transformed my ladies NA Veloster from sewing machine quiet, to something a lot more fun to drive, everyone who has a go loves the noises now, and it's still not very powerful!

[Elmura]

Wow. I have also deleted centre muffler. Roughly what cost for the exhaust bypass valve set up?

I did some of the work so costing for someone to do it may be hard. The valve itself was my second for this car. The first was a motorised unit from Ebay. It was slow to open & close, and the gears self destructed after a few months.
The new unit I got is vacuum operated so instant open & close, remote controlled. I had an exhaust shop fit a Y-piece and the butterfly valve at a spot just in front of the rear diff such that all equipment had space. I then wired it, fastened in the controller, vacuum hoses, T-piece etc.
The unit itself is, by memory, around $180.

I would have to say that VW would have a team of engineers and designed the intake that way for a reason, and performed test after test after test on such design.
If such a simple change would be a significant cost/performance/efficiency trade off then VW would have made the mod themselves as standard. You wouldnt get increase performance AND efficiency without affecting something else such as engine life.

To make the air flow more "laminar" a cross sectional grid would not do alot. Especially being so far way from the value intake, buy the time its gets there its most likely turbulent again. You would need the addition of a thicker guide such as a series of straws that go as close to the ignition point as possible.

You should re-read my post. I removed this grid which serves to block leaves, rubbish etc from getting into your airbox. This is designed to reduce the amount of filtering the air filter does. However, I'm not a typical owner, I optimise my cars from an engineering perspective, which means that I am aware of the implications - in this case, more frequent cleaning of the air filter (or replacement paper elements). I also spray cleaner on the MAF sensor every 20,000km. PS - It ain't simple to do these mods.

Similarly, the first mod of the intake scoop directing all air into the airbox does have an implication as well - the oil cooler doesn't get as cool an airflow over it. Again - I compensate by using premium synthetic oils changed every 10,000km, along with a new filter.

[xR360]

#Elmura
Haha, keep up the updates & I don't mind the crossover of topics, really keen on the centre muffler delete & now the vacuum bypass. Where did you get the quality one from?
I have seen the ones on eBay & wondered.. My Ol man is looking to get one for his hotrod also...
What sort of timeframe are you thinking for your prototype for the R36 / CC RAM design? After the house build of course.


Sent from my iPhone using Tapatalk

[eurobahn5]

I am also about to install aftermarket euro IV 200 cell cats and straight through rear mufflers this week. Also I have nearly completed my custom DIY foam pod cold air induction set up.

[Passat R36]

had a quick look at the inlet, I think the "blade" serves it's purpose, to prevent water getting into the air box. Imaging you driving at 100km/p in heavy rain or using pressure water to wash your car...

[eurobahn5]

Hi guys, I installed my DIY home job air intake today, nothing too flash. I also had fitted high flow cats and thru rear mufflers. The sound is quite amazing, it kind of somewhat resembles the R36 with the supersprint exhaust on that youtube video clip. I will try and get some audio of it in action and post it on here...