CAI - In Development

[mark@vagworx 0]

Hi everyone.

I'm currently in the development stages of producing a CAI (Cold Air Intake) System for the VR6.

Now, i'm off to speak to a Fabrication company later this afternoon to get the ball rolling. Initial thoughts are either to use Stainless steel or Aluminium tubing with a 3" bore, but this is to be confirmed.

I'm going to use my pipercross filter for development purposes but eventually i'm going to look at using a GREEN Cotton filter, which are MAF friendly!

Basically, if all goes well with the prototype i'm going to look at producing a CAI kit comprising of:

CAI tube

Green Cotton Air Filter

Stainless Clamps

2 x Samco end hoses

All fixings

It's a long way off yet, and all price dependant.

Who would be interested in a kit if developed??

[DundeeDub 0]

if it fits onto a bmc cda then i will be interested

[mark@vagworx 0]

if it fits onto a bmc cda then i will be interested

Have you got a BMC cannister kit already then?

[binliner 0]

are you talking about the bit between the filter and the throttle body? just replacing the plastic tube with a metal one or is there more to it than that?

[VR6Pete 1,455]

the BMC will take some beating in performance and cost...

[mark@vagworx 0]

the BMC will take some beating in performance and cost...

We'll see

It's all to do with cold air supply. How much is a BMC kit £180 odd? Hmmm

[mark@vagworx 0]

are you talking about the bit between the filter and the throttle body? just replacing the plastic tube with a metal one or is there more to it than that?

No not that bit.

From the MAF sensor down. See sample piccie. Basically in your case' date=' from where your BMC attaches.

[img']http://www.seatenthusiasts.co.uk/forum/attachment.php?attachmentid=12328&stc=1

[Valver 0]

I'd be interested - any idea on price?...

[binliner 0]

sounds interesting but I cant see the pic tell me more on sunday

[mark@vagworx 0]

I'd be interested - any idea on price?...

Not as yet, but no more than £200.

Got to get the prototype made and tested.

Was thinking about both a Polished finish and also a Black Powered Coated finish....again price dependant.

[mark@vagworx 0]

sounds interesting but I cant see the pic tell me more on sunday

Will do matey.

[VR6Pete 1,455]

160 I paid for BMC:)

I like the sound of the all metal tubing from the filter into the TB however, Ive currently got a bonrath power rhoar from the MAF to the throttle body (£45)

[Eat this 2]

id be intrested if it gave decent power and HUGE noise id b very intrested

[andy 0]

is the plan to have the filter located inside the wing, ie where the carbon canister sits? how are you planning to stop the filter from getting soaked in the rain? as for sound it shouldn't be noisier than a cone filter that bolts straight onto the maf

[mark@vagworx 0]

is the plan to have the filter located inside the wing' date=' ie where the carbon canister sits? how are you planning to stop the filter from getting soaked in the rain? as for sound it shouldn't be noisier than a cone filter that bolts straight onto the maf[/quote']

Yep, the final position of the air filter is likely to be somewhere near the bottom right hand side of the bumper, ie, where the square mesh grill is. The horn will probably need relocating to get maximum airflow.

As for use in the rain........well you can get waterproof but breathable jackets for the filters nowadays.....so that's the plan.

Might end up being a little louder than a cone on the MAF, as the noise may very well resonate through the tube.

Early days yet though.

[binliner 0]

Aah I see... I wondered if that was the plan when you were asking about the cc

[mark@vagworx 0]

[madmonkee 0]

i am already doing this

[madmonkee 0]

what my plan is..... remove the carbon canister and replace my 80mm intake pipe with a 5-6" yes INCH, pipe, (like the one from your tumble dryers) this will be mounted down the bottom by the grill/horn area. Come up through where the carbon canister was. Then up into a already sectioned off area. This will then ram air up into a sectioned off area under the bonnet with a "filter" on the end of the MAF completly sealed off from the rest of the engine bay. Should then create its own vacumn and draw air in from the wing (like standard induction) also from the ram pipe. If you look hard enough you can buy all this ready made.

[binliner 0]

but rather than duct air to the filter in the normal position he's talking about relocating it to down near the front bumper.... I dont think the hole left by the cc is big enough for a 6" pipe is it?

[madmonkee 0]

bit of moddin it will go in. I know whats being said but again i think thats already out surely. There isn't alot left thats hasn't been done already. My idea comes from a local vw racing team after lookin over there cars for a fair old bit. They got the 5-6 pipe up through that hole but not yet surrounded the filter. Aparently no need after you got all that air ramming up. Gotta be worth a bash. I'll let you all know when its done

[mark@vagworx 0]

I've made the first prototype, which i fitted to the car last night.

I've used sections of 3" bore stainless tubing and my original Pipercross Filter for the moment. If all goes to plan, it will eventually be a one piece item.

The filter now sits snuggly in the cavity just behind the front splitter near the square piece of mess in the front bumper. The filter's about 3-4" from the tarmac. I need to tweak the arrangement a bit in order to raise the filter away from ground thus protecting it a bit more.

Performance wise, the car pulls like a steam train all the way through the rev range and the noise is unbelieveable........is louder than just having the cone filter. I can't discribe the sound but it's raucous!

I'll try and get some pics up later.

[mark@vagworx 0]

Here's a few piccies of the CAI installed.

[VR6Pete 1,455]

question: what about if you have air conditioning....

question 2: what if you hit some standing water on the road?

[Eat this 2]

dumb question wheres the filter??