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Discussion Starter · #1 ·
Cold Air Intake - CAI finshed, anyone else interested?

You all may remember my first CAI<p><A HREF="http://forums.swedespeed.com/zerothread?id=43909" TARGET="_blank">http://forums.swedespeed.com/zerothread?id=43909</A><p><IMG SRC="http://img168.imageshack.us/img168/5053/1003453small7my.jpg" BORDER="0"><br><IMG SRC="http://img168.imageshack.us/img168/9485/1003451small7yl.jpg" BORDER="0"><br>Hose just was jammed into keyhole (which wasn't cut until last week)<br><IMG SRC="http://img234.imageshack.us/img234/5656/1004801small9pr.jpg" BORDER="0"><p>And the fact that despite not having a nozzle pointing into the wind, that is such high pressure area it did this to filter:<p><IMG SRC="http://img84.imageshack.us/img84/1610/1004804medium5fj.jpg" BORDER="0"><p><A HREF="http://forums.swedespeed.com/zerothread?id=55091" TARGET="_blank">http://forums.swedespeed.com/zerothread?id=55091</A><p>Well, I decided that I would get creative now that I have a dremmel. So, I made a custom hose outlet that fits inside of keyhole and seals...<p><IMG SRC="http://img455.imageshack.us/img455/1060/1004880small1jx.jpg" BORDER="0"><br><IMG SRC="http://img455.imageshack.us/img455/6825/1004879small3iy.jpg" BORDER="0"><br><IMG SRC="http://img455.imageshack.us/img455/8217/1004898small6tb.jpg" BORDER="0"><p>And put this 6"x2" ID nozzle (7"x3" OD) on the other end:<p><IMG SRC="http://img221.imageshack.us/img221/579/1004888small5hw.jpg" BORDER="0"><br><IMG SRC="http://img455.imageshack.us/img455/2725/1004890small5fg.jpg" BORDER="0"><p>I actually attached it with some shrinking joiner stuff, but I didn't have a camera with me at the time when I was having fun with the heat gun. Clamp would work as well...<p>What is really sad is the stock intake is only 8"x1.5" (12sq in), and doesn't stick directly into wind flow. My CAI intake effectively is 21sq in, and is perpendicular to the wind. Not only that, because it its form fitting, the bumper and the lower air dam act as extensions of the air intake, funnelling more air in.<p><IMG SRC="http://img455.imageshack.us/img455/7768/1004915small4lk.jpg" BORDER="0"><br><IMG SRC="http://img221.imageshack.us/img221/6901/1004916small4nl.jpg" BORDER="0"><p>Couple of notes, I decided to just re-use my 2.5" neoprene hose, but air intake has 2" outlet, so not really necessary. Also, I found higher quality 2" neoprene hose (lined ont he inside as well, wire not exposed to air)<br>and a spun aluminum 2" air outlet that wouldn't require dremmeling the valve hole, so airbox can be put back to stock in a flash (just need to trim down outlet flange to fit inside keyhole). <p>So, if I put this together as a kit, <p>6" x 2" ID offset rectangular nozzle<br>3 ft of 2" double walled neoprene hose (only really need 28")<br>2" spun aluminum air outlet<br>Clamps and shrink joiners<p>would people be interested? Cost would be between $100-$150 depending on how many orders. I have a source that will give a nice group buy discount on nozzles/outlets and joiners if I can get 15. You only really need a dremmel to do this (hole saw if you don't want to remove inner shroud). You don't even have to remove air box, although that does make it easier to dremmel out keyhole.<p>What I really like is that aside from hole in inner shroud, this can be removed and put back to stock very easily.. <p>Anyways, please post if you are interested... I'm very happy and thought I'd share.
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

i like it. nice work. i would love to do that myself. the price seems a bit high based on the materials needed. is something in that setup expensive to source?<p>do you have a picture of the intake scoop with the fog lamp grill off?<p><br><BR><BR>
<i>Modified by jasondew at 6:55 PM 3-18-2006</i>
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

"R" Kelly,<p>There is value and worth in the R&D you've done but with all due respect $100 seems high. There is also great value in getting it all as a kit, that saves a buyer time (ie. money) in shopping around to find all the right parts and saves in cutting them to size, etc. But if you consider the other recently posted "$10" design <A HREF="http://forums.swedespeed.com/zerothread?id=55463" TARGET="_blank">http://forums.swedespeed.com/zerothread?id=55463</A> you might agree that $100+ is too high. Let me explain further...<p>I realize your CAI kit would include a VERY nice inlet nozzle (6" x 2" ID offset rectangular nozzle<br>) and a custom grommet/flange that makes a great seal at the box keyhole, however, I don't see those pieces justyfying the $100+ price you are suggesting. Also, I see the $10 design as less invasive/destructive since it does not require cutting out the keyhole valve (please don't take offence to my choice of words, I mean no malice). Personally, I prefer not to cut out that valve in order to make returing the box to stock much easier. (You didn't explain how one would return his airbox to stock with your design.)<p>IMHO you should consider making a kit for less than $100 and that combines the low-cost of the $10 design and your excellent find on the two special parts (flange at the box and 4x2 inlet piece). Now that would be a good seller 'round here.<p>ps. I don't plan to make a competing kit or anything like that, I'm just suggesting what <I>I</I> think is a better and more cost-effective solution.<p>LTA<br>
 

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Discussion Starter · #4 ·
Re: Cold Air Intake - CAI finshed, anyone else interested? (jasondew)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>jasondew</b> »</i></TD></TR><TR><TD CLASS="quote">i like it. nice work. i would love to do that myself. the price seems a bit high based on the materials needed. is something in that setup expensive to source?</TD></TR></TABLE><p>The nozzle, aluminum air outlet (plastic one I used was 2.5" and required dremmeling out the valve hole) and shrink joiner are all pricey. Neoprene hose is only relatively inexpensive part. Could shave some if went with cheap clamps instead of shrink joiner, but was concerned about clamp getting in the way of inner bumper shroud.<p>
 

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Discussion Starter · #5 ·
Re: Cold Air Intake - CAI finshed, anyone else interested? (LTA)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>LTA</b> »</i></TD></TR><TR><TD CLASS="quote">"R" Kelly,<br>There is value and worth in the R&D you've done but with all due respect $100 seems high. </TD></TR></TABLE><p>And yet 12 people were going to pay $300 pre-buy for a system that wasn't even designed and didn't have ANY R&D. $399 Regular price... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/rolleyes.gif" BORDER="0"> <p><TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>LTA</b> »</i></TD></TR><TR><TD CLASS="quote">"Also, I see the $10 design as less invasive/destructive since it does not require cutting out the keyhole valve (please don't take offence to my choice of words, I mean no malice). Personally, I prefer not to cut out that valve in order to make returing the box to stock much easier. (You didn't explain how one would return his airbox to stock with your design.)</TD></TR></TABLE><p>Umm, the valve drops out and pops back in VERY easily. No cutting of airbox involved since I was going with more expensive spun aluminum outlet versus cheap plastic one I had.<p>The $10 design requires cutting a big hole in the bottom of your Airbox. How would you return that to stock? <p>Also, it looks like it only has 4 sq in opening. I think it is neat idea though. Although I don't know that he included the cost of the paint. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0">
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

I'm definately interested. I will echo what others are saying, it does seem a bit expensive for the parts needed... I had a computer reservoir made of solid delrin with extensive machine time for less than $100 <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/eek.gif" BORDER="0"> Anyway, I have a couple of questions, first, can i use my stock solid foglamp covers and just cut them out? Or do I need to buy the vented ones? Second, what airfilter is that you are using?
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>"R" Kelly</b> »</i></TD></TR><TR><TD CLASS="quote"><p>The $10 design requires cutting a big hole in the bottom of your Airbox. <B> How</B> <B>would you return that to stock? </B> <p> </TD></TR></TABLE><br>Hmm, a piece of large dia. duct tape would serve nicely. Tape over the hole, airbox is stock once more. This would work.<p>(BTW, I think you did a nice job <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> on yours)
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>"R" Kelly</b> »</i></TD></TR><TR><TD CLASS="quote"><p>And yet 12 people were going to pay $300 pre-buy for a system that wasn't even designed and didn't have ANY R&D. $399 Regular price... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/rolleyes.gif" BORDER="0"> </TD></TR></TABLE><p>There's one born every minute, eh!<p><TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>"R" Kelly</b> »</i></TD></TR><TR><TD CLASS="quote"> Umm, the valve drops out and pops back in VERY easily. No cutting of airbox involved since I was going with more expensive spun aluminum outlet versus cheap plastic one I had.<p>The $10 design requires cutting a big hole in the bottom of your Airbox. How would you return that to stock?</TD></TR></TABLE><p>Well I saw some cutting in that area and I didn't know the valve just pops out (I'm jumping the gun here since I don't even have my R yet and I've never had my hands on the airbox yet). <p><TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>"R" Kelly</b> »</i></TD></TR><TR><TD CLASS="quote"><p>Also, it looks like it only has 4 sq in opening. I think it is neat idea though. Although I don't know that he included the cost of the paint. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> </TD></TR></TABLE><br>That's why putting your nozzle on his pipe might be the best combo.. ooh, that sounds bit "off" sorry <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/eek.gif" BORDER="0"> <p>LTA<p><br>
 

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Discussion Starter · #9 ·
Re: Cold Air Intake - CAI finshed, anyone else interested? (nikhsub11)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>LTA</b> »</i></TD></TR><TR><TD CLASS="quote">That's why putting your nozzle on his pipe might be the best combo.. ooh, that sounds bit "off" sorry <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/eek.gif" BORDER="0"> </TD></TR></TABLE><p>That will so not work, but I'll let you figure out why. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/smile.gif" BORDER="0"> <p>btw, I would have been less offended if it was me with the pipe... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/tongue.gif" BORDER="0"> <p><TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>nikhsub11</b> »</i></TD></TR><TR><TD CLASS="quote">I'm definately interested. I will echo what others are saying, it does seem a bit expensive for the parts needed... </TD></TR></TABLE><p>Well, there is the original one I did, if you can find someone to split the neoprene hose cost (minimum 6' length for $41), you can do one for under $50. <p>But people were complaining it didn't look professional. And they doubted anything that didn't cost hundreds of dollars could be beneficial. Why so many signed up for vaporware that was $299 (the more expensive it is, the better, right?).<p>But people, neoprene hose ain't cheap. <br><IMG SRC="http://www.pegasusautoracing.com/Images/L/3620.JPG" BORDER="0"><p>Expensive high density polyethylene offset ducts ain't cheap.<br><IMG SRC="http://img510.imageshack.us/img510/7854/intake7yz.gif" BORDER="0"><p>Clamps are cheap. <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <p>And, paying to have suppliers ship to me isn't free. Mines done, so I'm good, I just thought I would throw out the idea, because if enough people were interested, I could get the expensive stuff at a group buy discount. <p>But you know, I got enough stuff to worry about, a busted knee, physical therapy, more than full time job, a huge GTG to finish organizing for everyone else, and a baby on the way in two weeks. <p>Now that I think about it, forget the group buy, I do not have the time. But feel free to use my ideas. <BR><BR>
<i>Modified by "R" Kelly at 9:55 PM 3-19-2006</i>
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

"R" Kelly no need to get upset over this... the 2 hardest parts to aquire are the funnel and the aluminum rings. The rest is cake. What is the cost for those items?
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>"R" Kelly</b> »</i></TD></TR><TR><TD CLASS="quote"> But feel free to use my ideas. </TD></TR></TABLE><br>That would be great! Can you tell us where you got the offset duct? <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0">
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? (nikhsub11)

<A HREF="http://www.quickcar.net/cooling/cp_bumpduct.html" TARGET="_blank">http://www.quickcar.net/cooling/cp_bumpduct.html</A><br>$19.95 for a single hose duct<p><A HREF="http://www.quickcar.net/cooling/cp_hose.html" TARGET="_blank">http://www.quickcar.net/cooling/cp_hose.html</A><br>10' of Neoprene hose $51.95<p>I am interested in the Double hose bumper duct, can anyone say Brake cooling??<p>-Caleb<br>
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? (nikhsub11)

R Kelly,<br>I'm in, tell me when, where, and how to pay. I really like the duct fitting down at the grill. I would like to know even if you don't get enough people to participate. Thanks-
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? (nikhsub11)

I like your system, but i think the smooth conduit really flows much better. It really only costs me $10, i'm not trying to sell anything,just help others improve their car. also, i don't know how much a can of black spray paint is in Germany, but it didn't set me back much.
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? (jasondew)

Kelly, it is a clean design, I would be interested. Sign me up. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0">
 

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Maybe I missed it somewhere but what are the real world benefits of this mod? Any before and after GTech, dyno, etc. data available? No, how about an educated guess from someone?<p>I might be interested but I need at least the illusion of some benefit first.
 

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Re: (rollie)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>rollie</b> »</i></TD></TR><TR><TD CLASS="quote">Maybe I missed it somewhere but what are the real world benefits of this mod? Any before and after GTech, dyno, etc. data available? No, how about an educated guess from someone?<p>I might be interested but I need at least the illusion of some benefit first.</TD></TR></TABLE><p>At full boost Jim Lill discovered vacuum develops in stock air box when testing with a manometer (probably due to the small 12 sq in stock air intake opening shown in above picture).<p>With my mod, you are essentially adding a 21 sq in ram air intake. Not only will this ensure more than enough air, but I believe at speed will create positive pressure in air box. When combined with high flow BMC air filter, will help turbo spool up even faster, and will definitely result in lower IAT, and quicker engine cool down (Jims testing confirmed last two).
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

Hey "R" Kelly, How would this work with the Evolve front Bumper? Would it be the same or easier? Or woul the mesh grills be more restirctive? Do things still line up?
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? ("R" Kelly)

Nice work RKelly. Its people like you that make these forums worthwhile, thanks for the effort! <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0">
 

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Re: Cold Air Intake - CAI finshed, anyone else interested? (juve021)

Do you think the CAI would be of any benefit even if my V70R MT is bone stock? Specifically, do you think it would help maintain some power even when it gets warmer outside? I guess I have no idea how hot the air inside the box gets from the engine heat compared to what's coming in under stock conditions. If it does heat up in there, then I would guess that extra inflow (even if it is 75-80 deg F) would help keep the temp down a bit and save some power. Any hope that this is correct?<p>Albert
 
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