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Upgraded Stock Airbox

junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
I've been looking for a quieter intake solution and decided to try modifying the stock intake box. Hopefully something that is quiet, grabs cold air, and flows close to my Neuspeed intake with RS Cold Air extension. Also, I'm curious if I will pick up a little more low-end torque.

So far I used the extra DEI reflective gold tape from my brake job to cover the bottom engine side of the air box. I also used clippers and a Dremel to remove the two rain flaps in the snorkel, any moulding ridges, and about half of the first air box fin that is intended on routing air to the drain hole. I removed enough of it to maintain most of that functionality while allowing the main portion of the airflow in the first segment to run over the body of the panel filter. Also, I ran over to EuroSport and picked up an itg panel filter. From what I can tell VWR might be a rebranded itg. :iono:

Either tonight or tomorrow, I'll relog my E85 blend with the GIAC Race file to make sure I am getting the same g/s. Also, I'll report back on the noise levels. After this I'm thinking that my engine bay will look close to stock.
 

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junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
:lol: It's so civilized! Makes me glad I have a full exhaust so I can hear what's going on!

Low-end torque feels great. :thumbsup: Will take logs tonight to see how it works with a K03 with most bolt-ons. :iono:

Did I say it is quiet?

I'll have a Black Neuspeed P-Flo with Heatshield, an optional larger angled, ovalized Neuspeed element that you can't buy anymore, and possibly vented grills for sale shortly.
 
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MKV727

MKV727

Go Kart Champion
Location
Tampa, FL
junker said:
:lol: It's so civilized! Makes me glad I have a full exhaust so I can hear what's going on!

Low-end torque feels great. :thumbsup: Will take logs tonight to see how it works with a K03 with most bolt-ons. :iono:

Did I say it is quiet?

I'll have a Black Neuspeed P-Flo with Heatshield, an optional larger angled, ovalized Neuspeed element that you can't buy anymore, and possibly vented grills for sale shortly.
Click to expand...

Looks good! I'm borrowing your idea with the gold heat wrap. How much is that wrap btw?

I'm anxious to see some logs too.
 
junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
MKV727 said:
Looks good! I'm borrowing your idea with the gold heat wrap. How much is that wrap btw?

I'm anxious to see some logs too.
Click to expand...

:happyanim: I bought it Amazon Prime with 2 day free shipping. It's actually more than I thought. $27 for 15' of the 1.5" tape and $34 for the 2" roll.

Here is the link:

http://www.amazon.com/DEI-010394-Reflect-A-GOLD-Tape-Roll/dp/B0039Z5TUY/ref=sr_1_5?s=automotive&ie=UTF8&qid=1343184620&sr=1-5&keywords=dei+gold

I'll have some logs posted later tonight. :thumbsup:
 
MKV727

MKV727

Go Kart Champion
Location
Tampa, FL
junker said:
:happyanim: I bought it Amazon Prime with 2 day free shipping. It's actually more than I thought. $27 for 15' of the 1.5" tape and $34 for the 2" roll.

Here is the link:

http://www.amazon.com/DEI-010394-Reflect-A-GOLD-Tape-Roll/dp/B0039Z5TUY/ref=sr_1_5?s=automotive&ie=UTF8&qid=1343184620&sr=1-5&keywords=dei+gold

I'll have some logs posted later tonight. :thumbsup:
Click to expand...

When I looked originally I only saw it in sheets. How much would you estimate is needed to wrap the heat shield attached to the engine cover?
 
junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
Here are the logs comparing the Neuspeed P-Flo (that was cleaned recently) versus the modified air box as described above*. (i.e. new itg filter element, ported, and DEI gold reflective tape)

*Note: Both runs were using OTC Race file and the same batch of ~E20. Also, ambient temperatures with the P-Flo pulls yesterday were slightly warmer.

With the modified engine cover, 3rd gear air mass increased from 169 to 179 g/s, where 4th gear increased from 167 to 172 g/s. Using the rough rule-of-thumb that 1 g/s ~ 0.8 hp shows a peak HP increase of 4-8 HP. :eye bulge:

Conclusion: Even though the temps from yesterday may have been slightly warmer, and the data comes from a single dataset I think it is pretty safe to say that the stock engine cover set-up as described above is at least as good as an engine bay P-Flo, perhaps up to 8 HP better. How much is due to the element and how much is due to the porting is unclear. IMO a Carbonio or modified OEM air box with itg element is an excellent intake solution that is also quiet. :thumbsup:
 

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junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
MKV727 said:
When I looked originally I only saw it in sheets. How much would you estimate is needed to wrap the heat shield attached to the engine cover?
Click to expand...

Interesting, I didn't think about tacking the integrated heat shield but I would think 1'x1' would be sufficient. :iono:

I think I used about 2/3 of the 1.5 " x 15' roll that I had from my brake job :happyanim:.
 
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junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
This is picture of the stock looking engine bay that is about to mug and maul you...:evil:

The proverbial sleeeper... No officer my car is stock I promise... Can we check under the hood sir? Well damn Jethrow I reckon it looks minty pristine to me. Let's leave this nice GTI owner alone and go jack with boy racer TC and FR-S owners :mad:

Officers walking away overheard saying" that GTI is dope yo, so much better than that ricer stuff.. :lmao:
 

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the bruce

the bruce

Go Kart Champion
Location
land
Car(s)
Golf GTI Mk.V 2008
Hello Junker,

had similar thoughts some years ago. :biggrin:
I also removed the rain flap in the snorkel and partly closed the drain hole.

:thumbsup:
 
MKV727

MKV727

Go Kart Champion
Location
Tampa, FL
junker said:
Here are the logs comparing the Neuspeed P-Flo (that was cleaned recently) versus the modified air box as described above*. (i.e. new itg filter element, ported, and DEI gold reflective tape)

*Note: Both runs were using OTC Race file and the same batch of ~E20. Also, ambient temperatures with the P-Flo pulls yesterday were slightly warmer.

With the modified engine cover, 3rd gear air mass increased from 169 to 179 g/s, where 4th gear increased from 167 to 172 g/s. Using the rough rule-of-thumb that 1 g/s ~ 0.8 hp shows a peak HP increase of 4-8 HP. :eye bulge:

Conclusion: Even though the temps from yesterday may have been slightly warmer, and the data comes from a single dataset I think it is pretty safe to say that the stock engine cover set-up as described above is at least as good as an engine bay P-Flo, perhaps up to 8 HP better. How much is due to the element and how much is due to the porting is unclear. IMO a Carbonio or modified OEM air box with itg element is an excellent intake solution that is also quiet. :thumbsup:
Click to expand...

Fantastic :thumbsup:

People won't look at me like I'm crazy anymore when I tell them my Carbonio set up outperforms my old P-Flo. I have another person who achieved very similar results.

BTW, I ordered the DEI gold wrap thanks for the idea!
 
junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
the bruce said:
had similar thoughts some years ago. :biggrin:
I ... partly closed the drain hole.
Click to expand...

This IS a good idea!

Also, my high fuel trim from running E20 came down from 18% to 12.5% last night with the stock MAF housing and screen. :thumbsup:
 
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F

Fernas

Mexibahn Native
Location
Guadalajara, Mexico.
Car(s)
MKV GLI "Red Baron"
Good work man, outperformed an aftermarket intake and still looking stock, i have a question though, your location says Newport Beach, i would asume that you were at sea level when running those logs, is not the 180g/s peak a bit low?? i have peaked at that just yesterday in 2nd/3rd gear and im at 5500ft high above the sea level, im used to see my MAF readings are lower than what i can find on the internet and im REVO S2+, and Forge WG.
 
VWTiger

VWTiger

I am the Stig
Location
MD
junker said:
Well damn Jethrow I reckon it looks minty pristine to me. Let's leave this nice GTI owner alone and go jack with Scions, Nissans, and Sentra :mad:

Officers walking away overhear saying" that GTI is dope yo, so much better than that ricer stuff.. :lmao:
Click to expand...

:lol:

I was looking at a drop in filter today instead of a full CAI earlier today before I saw this thread. Good stuff Junker. I may srsly pull the trigger on this too
 
junker

junker

You get an 'F'!
Location
Berkeley
Car(s)
MkV GTI FSI
Yeah I think so too but I am currently running a batch of 20-25% ethanol with a leaner 100 octane race file so I was mostly interested in the g/s change. I'll rerun when I'm back on straight gas and the pump file and update this thread.
 
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