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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > 'Mr. 5 Intake'... Zasquatch style



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      05-25-2011, 06:37 AM   #1
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'Mr. 5 Intake'... Zasquatch style

For the past month or so I've been collecting the various items needed to build a 'Mr. 5' Intake... Spare airbox, Macht Schnell panel filter, etc.

I had a hard time finding a 3" flange for a reasonable price without being some cheaply made plastic M.I.C. junk, so I decided to make my own couplers out of 6061 Aluminum. I designed the parts and my friend made them for me on his milling machine.

I got a chance to install the flange into the airbox last night and am quite happy with the results. I chose to use a Silicone II household/RV/Auto gasket maker/sealant to affix the flange, as it has a very high temperature rating (400 deg F), is waterproof, grease and oil resistant, stays rubbery and will never crack. Also notice that I had him chamfer all the edges that will see air - prob won't make any difference, but being an engineer I had to make things aerodynamic











I'll keep this updated as the project moves along. When I was doing my research I found it very helpful to see the various techniques and tweaks people did to the basic Mr. 5 idea. And of course, THANK YOU MR.5 for this genious design
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      05-25-2011, 06:40 AM   #2
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Very clean!
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      05-25-2011, 06:58 AM   #3
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Very clean indeed!
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      05-25-2011, 07:06 AM   #4
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Nice!
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      05-25-2011, 07:14 AM   #5
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that looks pretty good!
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      05-25-2011, 07:14 AM   #6
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Awesome! Care to post the drawings for this?
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      05-25-2011, 07:16 AM   #7
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Please do consider this version of Mr. 5 with K&N Apollo:

http://www.e90post.com/forums/showthread.php?p=8762970

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      05-25-2011, 07:28 AM   #8
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Quote:
Originally Posted by tscdennab View Post
Please do consider this version of Mr. 5 with K&N Apollo:

http://www.e90post.com/forums/showthread.php?p=8762970

Very nice as well! How difficult was it to drill the hole using a hole saw and hand drill? Did you use any braces or jigs to ensure straight drilling? I might be overthinking it as my stock airbox has been sitting in the attic in a box since I installed my DCI over a year ago so it might make more since once I look at it in more detail in person. lol
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      05-25-2011, 07:37 AM   #9
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Quote:
Originally Posted by ironman1982 View Post
Very nice as well! How difficult was it to drill the hole using a hole saw and hand drill? Did you use any braces or jigs to ensure straight drilling? I might be overthinking it as my stock airbox has been sitting in the attic in a box since I installed my DCI over a year ago so it might make more since once I look at it in more detail in person. lol
Thanks guys.

I wedged the box in a big vice and chose my center carefully. After that it's the point of no return so you just have to be confident in your location lol.

I did find having the extra airbox very helpful. I took the hole saw bit to the car and looked at various positions and how they interacted with the DVs and underhood bits. I chose a spot slightly off-center, a tad forward. Since the side of the box has a nice square grid it was easy to relocate that position on the airbox under the knife.
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      05-25-2011, 07:37 AM   #10
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Quote:
Originally Posted by ironman1982 View Post
Very nice as well! How difficult was it to drill the hole using a hole saw and hand drill? Did you use any braces or jigs to ensure straight drilling? I might be overthinking it as my stock airbox has been sitting in the attic in a box since I installed my DCI over a year ago so it might make more since once I look at it in more detail in person. lol
You mean electric hand drill. It is much easier than you would expect, just hold the airbox between your legs while standing up and drill with a holesaw which has a guidance drill bit inside. Make sure you mark the center spot with a white marker or similar. Use a high-RPM drill (non battery operated) in order to cut perfectly in that plastic.
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      05-25-2011, 07:54 AM   #11
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Awesome! Care to post the drawings for this?
PM me your email and I can send it to you.
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      05-25-2011, 08:03 AM   #12
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Quote:
Originally Posted by tscdennab View Post
You mean electric hand drill. It is much easier than you would expect, just hold the airbox between your legs while standing up and drill with a holesaw which has a guidance drill bit inside. Make sure you mark the center spot with a white marker or similar. Use a high-RPM drill (non battery operated) in order to cut perfectly in that plastic.
lol...yeah...I assumed that...didn't think anyone would use an actual hand drill for this....I phrased it like that to differentiate that it wasn't a drill press.

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PM me your email and I can send it to you.
PM sent...thanks!
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      05-25-2011, 08:36 AM   #13
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Nice. Looks like it will be a Dinan style intake.
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      05-25-2011, 08:47 AM   #14
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I attempted the same thing, but I couldn't get the hose to fit in the wheel well. I have adapative steering and I think something is getting in the way of getting the hose to fit
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      05-25-2011, 09:01 AM   #15
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I attempted the same thing, but I couldn't get the hose to fit in the wheel well. I have adapative steering and I think something is getting in the way of getting the hose to fit
You you have a much better chance to work things out if you take out the headlight (it's easy, disconnect the socket and unscrew the 2 top screws).
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      05-25-2011, 09:44 AM   #16
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That looks really good!
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      05-25-2011, 03:18 PM   #17
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That looks great!
It is interesting to see another TAKE on the same challenge from a fellow engineer.

Here's mine:




My goal was to put the flange on the outside for as little intrusion into the airbox as possible (to minimize turbulence). I used 2 gaskets, cap screws with nuts and lock washers, no sealant. My flange started off as a "cheap plastic" Spectre flange from Advance. I turned it, shaved it, drilled new bolt holes, and painted it.




Pictures "under the knife":





The cone filter coupling started life as a real-estate info tube from Home Depot!


Last edited by bahn stormer; 08-29-2011 at 03:45 PM.
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      05-25-2011, 03:23 PM   #18
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Cool
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      05-25-2011, 03:34 PM   #19
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Nice job BS, it's very cool to see so many different approaches to the same project. Custom parts are fun
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      05-25-2011, 04:55 PM   #20
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Do you think that at freeway speeds, that the slightly pressurized air from the front air intakes just blows out this new air duct the wrong way? How do you know which way the air flows in your new air duct?
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      05-25-2011, 04:58 PM   #21
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clean work
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      05-25-2011, 05:51 PM   #22
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Looks clean so far this is the route i want to take for my car.
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