Airbox replacement and improved inlet

[chrisP]

I have completed a little project that I have wanted to do for a long time. The standard airbox always seemed inefficient in its design, with most of the air being drawn through a small proportion of the filter. So using the information that Marie put on here regarding the Honda Civic airbox being about the right size I jumped in and brought one to experiment with. Sure it fits in place well and has a cross flow design.
So I had various things to sort out:
1. A new inlet adapter for the turbo to accept the thicker pipe diameter
2. Mounting the airbox somehow
3. Creating a new inlet pipe
4. Working out how to plumb in the air sensor

I measured many times and came up with a design for the inlet, 3D printed it to make sure it would fit before having it machined
The airbox will sit on some aluminium plates that I have designed, partially using the existing chassis mounting points and extending a chassis bolt
I created a wooden buck for a new pipe, and created it in Carbon Fibre
This was a 3D printed boss

After initial testing I can report back that there a dramatic improvement in Turbo response and spool up, so much so that on cold days It will hit the boost limit.... So I will have to look at that. The intake sound, in my ears is much better.

A few photos

[Tuga2112]

i wouldnt think the standard airflow was restrictive.

you getting the overboost problem is likely to be the wastegate getting stuck probably due to some of the fretcling you did when installing the pipes.

i only know of shark being a highli modded M100. maybe others famliiar with the car can recall if it had an upgraded intake and air filter due to necessity or not.

[Geordie]

Hi ChrisP
I’ve been pondering about intake mod for a while ,unfortunately I don’t have access to a 3d printer and being an old bugger not sure if I have enough technical know how to use one ,I’ve been searching for upgraded replacement parts for a while now ,your setup looks good but like I said all my ideas rely on purchasing (not manufacturing) parts ? So if anyone is out there whose done an alternative setup I would be very interested
Geordie

[chrisP]

Hi Geordie
Thanks for the words. I don't think that anyone makes an alternative, but I have seem people use a generic cone filter and silicon pipe to the turbo. I can look at getting a price for the aluminium turbo adapter machining and work out how much the carbon tube and mounts cost to make. The other bits would be the filter box itself (mine came from ebay), silicon tube, the jubilee clips and the ducting pipe that goes from the original intake. Its not hard to fit, just a bit fiddly.

When I looked at the old filter, there was definitely an increased build up of detritus where the pipe leads off to the turbo indicating that the filter is not working as a whole just one section. The highest bhp engine I could find that it works in is at 197bhp 2.0 showing that it will cope with higher airflow, but even that car seems to have its filter box changed later on, for the cross flow design.

The reason that there is possibility of boost creep, is the same as when better flowing exhausts are fitted to the Elan - the turbo can work more efficiently and isn't restricted, nothing to do with "fretcling" that you talk of Tuga2112, As I say I was following on from the work Marie did, as she found an airbox that was available and fitted.

Cheers
Chris

[Geordie]

Cheers Chris
Any help with upgrade air filter intake would be gratefully appreciated,
There’s a few people who say the sports (PNM) filter helps ,but again ,there’s some comments this can cause turbo wear ?
Regards
Geordie

[simonbuk]

Interesting. As it's a Maestro/Montegro(?) unit I doubt if lots of development went I to that area ?!

[AJSGSE1990]

Cheers Chris
Any help with upgrade air filter intake would be gratefully appreciated,
There’s a few people who say the sports (PNM) filter helps ,but again ,there’s some comments this can cause turbo wear ?
Regards
Geordie

Can I make a suggestion, on both my Lancia Integrales the issue has always been the exhaust side and intercooler core more than the intake. That's where the biggest difference is, then its inlet air temperature and last flow rate.

Unfortunately, they are all in reverse expense order. The IC is a pure packaging problem. Potentially possible if you can squeeze a 60mm core in front of the main radiator. However then you next limit is exhaust size and at 2.25" or 2.5" max you are probably limited to 300bhp max at 1.5bar, just as an idea. But the IC core would handle more. Anyway, the point is that intake on a Turbo is not critical as much as the other bits, as far as I have seen, on the dyno on my cars it made near zero difference.

IC IDea.jpg

[Tuga2112]

on both my Lancia Integrales

now your just bragging

[AJSGSE1990]

on both my Lancia Integrales

now your just bragging

Now one who has ever worked on a Lancia has bragged about it, unless they are getting paid to fix it!!!!

The Lotus is a dream to work on in comparison.

[Tuga2112]

the Elan is a dream to work in within the lotus range.

i have tried to help friends with Europa and Elises....

even compared to my celica. the elan engine bay is a doodle.

changing the spark plugs on this toy requires the water to air intercoler to be moved... draining the coolant


i havent got round to do the timing belt on my MR2 yet... that is likely more trouble than the Elan as well..

if you want an easy car to work in. the Saab93 and fiat seicento have been a breeze in my experience.

[RonR]

Looks like the alternator's a bit easier than the M100's though......