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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 > DIY: N54 Hybrid Intake System



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      03-18-2012, 12:47 PM   #1
vasillalov
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Exclamation DIY: N54 Hybrid Intake System

1. Right click HERE and Save as...

Enjoy!
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      03-18-2012, 12:48 PM   #2
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      03-18-2012, 12:59 PM   #3
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Very very clean job. Thanks for sharing man.
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      03-18-2012, 01:29 PM   #4
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I know Helix Motorsports has made that exact same intake design for a while now... Any testing / Dyno's? I'm really against sucking in hot air (personal preference)... and I'm inclined to think that the vast majority of the air would preferentially be drawn from the added filter as the resistance is probably much lower than the stock airbox route. So this may be considered slightly better than a DCI in the sense that you are getting at least a little bit of cool air.
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      03-18-2012, 01:43 PM   #5
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This is interesting.

But I don't trust the factory rubber seal on the stock air box. They look cheap and will become loose very fast under heat. Which means it may will have a leak, if it leaks. Dust will go into the engine.

Maybe not that bad, but personally, I like to remove the air box.
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      03-18-2012, 03:19 PM   #6
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I really dont see it being much more effective than a DCI for cooler air with out a heat-shield... Does look good though.
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      03-18-2012, 04:42 PM   #7
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Quote:
Originally Posted by skim7x View Post
I know Helix Motorsports has made that exact same intake design for a while now... .
True. I borrowed the design from Helix, however if you read carefully, there are few key differences:

1. Helix uses 2-inch pipe, mine has 3-inch pipe
2. Helix requires more extensive modifications to the plumbing for the DVs, mine needs just a 90-degree coupler.

Helix system is really good, and that's why I based mine off theirs. I just thought of improving things a little bit.
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      03-18-2012, 04:43 PM   #8
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I really dont see it being much more effective than a DCI for cooler air with out a heat-shield... Does look good though.
Half of the air comes through the stock air box, the other half from the secondary filter. So *in theory* it should produce slightly cooler intake temps. I am yet to test this.
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      03-18-2012, 04:52 PM   #9
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Quote:
Originally Posted by vasillalov View Post
True. I borrowed the design from Helix, however if you read carefully, there are few key differences:

1. Helix uses 2-inch pipe, mine has 3-inch pipe
2. Helix requires more extensive modifications to the plumbing for the DVs, mine needs just a 90-degree coupler.

Helix system is really good, and that's why I based mine off theirs. I just thought of improving things a little bit.
That's awesome... Love the ingenuity.

Quote:
Originally Posted by vasillalov View Post
Half of the air comes through the stock air box, the other half from the secondary filter. So *in theory* it should produce slightly cooler intake temps. I am yet to test this.
I still think that >50% of the flow will come from the secondary filter and <50% from the stock airbox... but you're absolutely right in that we'll need testing to verify... maybe I'll be surprised!
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      03-18-2012, 05:04 PM   #10
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The stock airbox also has an aFe Pro Dry S filter and not the stock paper one. I'd have to measure total filter area and compare. The important thing for me was that the filter media is the same in the airbox and on the cone filter.
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      03-18-2012, 05:05 PM   #11
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Nice DIY...Looks clean as hell
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      03-18-2012, 05:17 PM   #12
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Quote:
Originally Posted by vasillalov View Post
Half of the air comes through the stock air box, the other half from the secondary filter. So *in theory* it should produce slightly cooler intake temps. I am yet to test this.
Now I understand your theory,

stock (cool air coming in) + your creation (more air flow) = more cool air flow! sounds good in paper, now lets see the results! if it looks good im definitely doing this.
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      03-18-2012, 05:20 PM   #13
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Now I understand your theory,

stock (cool air coming in) + your creation (more air flow) = more cool air flow! sounds good in paper, now lets see the results! if it looks good im definitely doing this.
Yep. That's the idea -> Uncork the stock air box and add more flow via a secondary air filter.
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      03-18-2012, 05:23 PM   #14
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Quote:
Originally Posted by vasillalov View Post
The stock airbox also has an aFe Pro Dry S filter and not the stock paper one. I'd have to measure total filter area and compare. The important thing for me was that the filter media is the same in the airbox and on the cone filter.
Ah... yeah that should help... then the only difference between the two would be the tortuosity of the stock airbox creating more resistance, then I could see it getting close to 50/50...

Damn, I just bought an aFe Stg2... maybe I should re-sell it and try this...
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      03-18-2012, 06:09 PM   #15
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Not liking this compromise. Use a K&N Apollo enclosed filter instead of the secondary filter and route the included hose to the bumper. What's so hard ?
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      03-20-2012, 07:17 AM   #16
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bump for those who missed it the other day.
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      03-20-2012, 07:19 AM   #17
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great DIY Vas and very good solution! might give it a go!
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      03-20-2012, 09:21 AM   #18
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That's got to be one of the cleanest looking DIY jobs I've seen...nice work!

Now you've got me wondering if I could fab my Stett CAI into something like this but keeping the second filter down in the fender well. (I really like the colder air it pulls.)
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      03-20-2012, 09:29 AM   #19
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I'd like to see somebody take this and run it down for a real cold air intake system. Would be nice if somebody had the time to test using all or mostly off the shelf parts that people could assemble into a kit.
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      03-20-2012, 09:59 AM   #20
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I'd like to see somebody take this and run it down for a real cold air intake system. Would be nice if somebody had the time to test using all or mostly off the shelf parts that people could assemble into a kit.
Very doable. I've thought about this too. You'll need a 60 degree bend and a few more pipes, but it is definitely doable. I just wanted to be able to keep a close eye on the cone filter without having to disassemble anything.
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      03-20-2012, 01:21 PM   #21
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Great DIY...loving it.

May I ask how much does it cost all together?
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      03-20-2012, 01:24 PM   #22
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Under $200 for all parts, not counting the OEM airbox. I purchased one from here for additional $80.00 in case I messed up during my first attempt.
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