E90Post
 


VIBE Motorsports
 
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



Reply
 
Thread Tools Search this Thread
      05-25-2011, 06:37 AM   #1
Zasquatch
Captain
United_States
11

 
Zasquatch's Avatar
 
Drives: '07 BMW 335i
Join Date: Sep 2010
Location: CT


Posts: 622
iTrader: (15)

Garage List
2007 BMW 335i  [0.00]
'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
Appreciate 0
      05-25-2011, 06:40 AM   #2
PiZauL
I6 + TT = FTW
22

 
Drives: 07 treetree5i
Join Date: Jan 2010
Location: Baltimore, MD


Posts: 815
iTrader: (2)

Very clean!
Appreciate 0
      05-25-2011, 06:58 AM   #3
vasillalov
Mad Linux Guru On The Loose
Bulgaria
80

 
vasillalov's Avatar
 
Drives: 2008 335i Sedan
Join Date: Aug 2009
Location: Chicago, IL


Posts: 4,178
iTrader: (3)

Garage List
2008 335i E90  [4.00]
Very clean indeed!
__________________
Equal Opportunity Harasser!
6MT | COBB | AR | AE | Forge DV | HPF | P3 Gauge | Hybrid Intake | O.S.Giken TCD | All M3 bits | TCKLine
Appreciate 0
      05-25-2011, 07:06 AM   #4
dzenno
Banned
Canada
114

 
Drives:
Join Date: Feb 2006


Posts: 5,883
iTrader: (1)

Nice!
Appreciate 0
      05-25-2011, 07:14 AM   #5
MKE_M3
Lieutenant Colonel
United_States
23

 
MKE_M3's Avatar
 
Drives: 2011 e90 M3
Join Date: Feb 2009
Location: Milwaukee, WI


Posts: 1,685
iTrader: (0)

that looks pretty good!
__________________
Appreciate 0
      05-25-2011, 07:14 AM   #6
ironman1982
Private
United_States
1

 
ironman1982's Avatar
 
Drives: 335i
Join Date: Mar 2009
Location: GA


Posts: 93
iTrader: (5)

Awesome! Care to post the drawings for this?
Appreciate 0
      05-25-2011, 07:16 AM   #7
tscdennab
Banned
54

 
Drives: BMW 335i
Join Date: Oct 2010
Location: Europe


Posts: 1,811
iTrader: (0)

Garage List
2008 BMW  [3.12]
Please do consider this version of Mr. 5 with K&N Apollo:

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

Appreciate 0
      05-25-2011, 07:28 AM   #8
ironman1982
Private
United_States
1

 
ironman1982's Avatar
 
Drives: 335i
Join Date: Mar 2009
Location: GA


Posts: 93
iTrader: (5)

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
Appreciate 0
      05-25-2011, 07:37 AM   #9
Zasquatch
Captain
United_States
11

 
Zasquatch's Avatar
 
Drives: '07 BMW 335i
Join Date: Sep 2010
Location: CT


Posts: 622
iTrader: (15)

Garage List
2007 BMW 335i  [0.00]
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.
Appreciate 0
      05-25-2011, 07:37 AM   #10
tscdennab
Banned
54

 
Drives: BMW 335i
Join Date: Oct 2010
Location: Europe


Posts: 1,811
iTrader: (0)

Garage List
2008 BMW  [3.12]
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.
Appreciate 0
      05-25-2011, 07:54 AM   #11
Zasquatch
Captain
United_States
11

 
Zasquatch's Avatar
 
Drives: '07 BMW 335i
Join Date: Sep 2010
Location: CT


Posts: 622
iTrader: (15)

Garage List
2007 BMW 335i  [0.00]
Quote:
Originally Posted by ironman1982 View Post
Awesome! Care to post the drawings for this?
PM me your email and I can send it to you.
Appreciate 0
      05-25-2011, 08:03 AM   #12
ironman1982
Private
United_States
1

 
ironman1982's Avatar
 
Drives: 335i
Join Date: Mar 2009
Location: GA


Posts: 93
iTrader: (5)

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.

Quote:
Originally Posted by Zasquatch View Post
PM me your email and I can send it to you.
PM sent...thanks!
Appreciate 0
      05-25-2011, 08:36 AM   #13
onesuperboi
Major
United_States
21

 
onesuperboi's Avatar
 
Drives: '08 e92 335i COBB 4.01 Stage 1
Join Date: Aug 2008
Location: Bay Area, CA (Alameda)


Posts: 1,342
iTrader: (6)

Nice. Looks like it will be a Dinan style intake.
Appreciate 0
      05-25-2011, 08:47 AM   #14
i2iSTUDIOS
Captain
22

 
i2iSTUDIOS's Avatar
 
Drives: BMW 335i Coupe
Join Date: Mar 2008
Location: Cincinnati, OH


Posts: 869
iTrader: (1)

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
__________________
2007 E92 335i / 6MT / Monaco Blue Metallic / Gray Dakota Leather / Comfort Assist / Premium / Sport / Heated Seats / Navi / Active Steering / Active Cruise Control / Park Distance Control / Rear Sunshade / Sirius MODS PicoTray / M3 Steering Wheel / Front OEM Aero Lip / Bimmian Aluminum Pedals / CDV / Ram Air Scoops / Painted Reflectors / HID 5000k / LED Angels / M Perf. Shifter / Euro Light Switch / 8500 x50 / Center Armrest Pouch / JB4 / BT
Appreciate 0
      05-25-2011, 09:01 AM   #15
tscdennab
Banned
54

 
Drives: BMW 335i
Join Date: Oct 2010
Location: Europe


Posts: 1,811
iTrader: (0)

Garage List
2008 BMW  [3.12]
Quote:
Originally Posted by i2iSTUDIOS View Post
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).
Appreciate 0
      05-25-2011, 09:44 AM   #16
Mr. 5
Modder Raider
Scotland
267

 
Mr. 5's Avatar
 
Drives: M3
Join Date: Apr 2007
Location: Surf City, HB


Posts: 8,626
iTrader: (31)

Garage List
2007 e90 335i  [4.00]
That looks really good!
__________________
e36 M3 Coupe, e36 325i Sedan
e90 335i--SOLD

Best 60-130-------------9.15 Seconds------------------WWW.MR5RACING.COM
Appreciate 0
      05-25-2011, 03:18 PM   #17
bahn stormer
Taking the dog out for some exercise.
United_States
6

 
bahn stormer's Avatar
 
Drives: 07 E90 335i 6MT, 65 MGB
Join Date: Feb 2008
Location: PA/Mexico


Posts: 527
iTrader: (3)

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.
Appreciate 0
      05-25-2011, 03:23 PM   #18
lamia2super
Colonel
United_States
40

 
lamia2super's Avatar
 
Drives: 335i
Join Date: May 2008
Location: Miami Beach, FL


Posts: 2,493
iTrader: (4)

Garage List
2007 335i  [5.00]
Send a message via AIM to lamia2super
Cool
Appreciate 0
      05-25-2011, 03:34 PM   #19
Zasquatch
Captain
United_States
11

 
Zasquatch's Avatar
 
Drives: '07 BMW 335i
Join Date: Sep 2010
Location: CT


Posts: 622
iTrader: (15)

Garage List
2007 BMW 335i  [0.00]
Nice job BS, it's very cool to see so many different approaches to the same project. Custom parts are fun
Appreciate 0
      05-25-2011, 04:55 PM   #20
CobraMarty
Lieutenant
12

 
CobraMarty's Avatar
 
Drives: 2007 328xi Coupe
Join Date: Sep 2010
Location: PA


Posts: 504
iTrader: (5)

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?
__________________
2007 328xi E92 Coupe // 6 MT-Crimson Red, Black Interior, Brushed Silver Trim//Sport Seats//BMW Perf. SW Alcantara//CF Roof, Front Lip, Trunk Lip Spoilers//18" 197, F-5mm, R-15mm Spacers//Akebono Euro Ceramic Pads//MGP Red Caliper Covers//BMW Alarm System//BMW CF Perf. Strut Brace//LUX H8 v3.0 AE//6k HID Fogs//BMW PE//Macht Schnell Intake Scoops//BMW EURO Intake//AA Tune//188AWHP-->196AWHP-->216AWHP//SOON- 3 Stage Intake Manifold!
Appreciate 0
      05-25-2011, 04:58 PM   #21
the infamous...
Relapsed Bimmerpost Addict
United_States
423

 
the infamous...'s Avatar
 
Drives: like I'M BOUT THAT LIFE
Join Date: Jul 2008
Location: PARADISE aka CANES COUNTRY


Posts: 17,534
iTrader: (0)

clean work
__________________


"simple is clean" -The ///ModFather
Appreciate 0
      05-25-2011, 05:51 PM   #22
Island Road
Captain
10

 
Drives: 335i
Join Date: Mar 2011
Location: Boston


Posts: 747
iTrader: (2)

Garage List
2008 335i  [5.00]
Looks clean so far this is the route i want to take for my car.
Appreciate 0
Reply

Bookmarks

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -5. The time now is 11:40 AM.




e90post
Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
1Addicts.com, BIMMERPOST.com, E90Post.com, F30Post.com, M3Post.com, ZPost.com, 5Post.com, 6Post.com, 7Post.com, XBimmers.com logo and trademark are properties of BIMMERPOST