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gsi8v
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Posted: 20 May 2019, 00:13 |
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Upgraded to a Flatbed Filter |
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Joined: 27 Jun 2008, 21:27 Posts: 147
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Hey guys, I am looking to start building a portfolio of experience in building custom induction systems that is practical in theory– improves air intake velocity speed and density – and practical in design – easy to install/uninstall - with a top quality finish. I did this set up for the OEM look but with the best possible performance. Here’s what I did to it. Air box – Completely redesigned the bottom of the filter housing by closing off a section inside and adding a second cold air feed (50mm) for a smoother air flow through the air box. I removed the snorkel from the lid, filled away some of the grooves inside the lid for smoother airflow and on the outside for a unique look. The entire airbox was sanded down to a smooth finish, all rough edges and corners were smoothed.
Rubber air intake tube with IAT sensor – no changes by a good clean.
Throttle body – I stripped it down for a thorough clean. The flange was filled in a shape of a trumpet to open it from 57mm to 63mm. The rest of the bore was left standard size with 45mm butterfly. The inside including butterfly was polished – starting at 180grit and finishing at 320grit. The TPS was recalibrated using a voltmeter (0.6v at idle with butterfly closed and 4.6v at WOT) All chrome parts were cleaned and polished, and the airbox and throttle was finished in high heat Matt black paint. I sold this with the K&N panel filter (had an old while laying around) to my buddy with a Corsa lite 1.4. It gave a noticeable difference in acceleration through the gears with a nice induction roar, purely because of the air flowing faster.
Hope you like my work! More pictures to follow
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PSX_20190520_000835.jpg [ 348.09 KiB | Viewed 5997 times ]
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PSX_20190520_000847.jpg [ 337.76 KiB | Viewed 5997 times ]
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_________________ 2002 Opel Corsa Gsi ltd 1.6 Custom cold air induction system Polished throttle body (53mm) OEM exhaust manifold 50mm stainless steel straight through exhaust system Smash & grab tint Webasto tilt and slide (factory fitted) Style inspired by Opel Motorsports
Last edited by gsi8v on 20 May 2019, 20:29, edited 1 time in total.
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Corsa Addict
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Posted: 20 May 2019, 07:49 |
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Joined: 29 May 2007, 13:54 Posts: 49707 Location: Paarl...ex Durbs
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Looks neat. Well done
Price range? You planning on mass production?
_________________ Opel Club Cape Town Member
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gsi8v
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Posted: 20 May 2019, 19:42 |
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Upgraded to a Flatbed Filter |
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Joined: 27 Jun 2008, 21:27 Posts: 147
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Pics of the air box modifications.
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File comment: Redesigned filter house. The left side of the airbox was closed. I did this for two main reason: 1. To eliminate disruption of air flow in the air box. 2. To suck more air through the cold air feeds by reducing the space inside the air box.
PSX_20190520_162522.jpg [ 228.67 KiB | Viewed 5980 times ]
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File comment: Second cold air feed - 50mm diameter - fitted at the bottom left hand side of the airbox.
PSX_20190520_162512.jpg [ 244.33 KiB | Viewed 5980 times ]
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File comment: Before (top) and after (bottom)
PSX_20190520_192421.jpg [ 381.95 KiB | Viewed 5980 times ]
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_________________ 2002 Opel Corsa Gsi ltd 1.6 Custom cold air induction system Polished throttle body (53mm) OEM exhaust manifold 50mm stainless steel straight through exhaust system Smash & grab tint Webasto tilt and slide (factory fitted) Style inspired by Opel Motorsports
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gsi8v
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Posted: 20 May 2019, 19:50 |
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Upgraded to a Flatbed Filter |
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Joined: 27 Jun 2008, 21:27 Posts: 147
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gsi8v
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Posted: 20 May 2019, 19:59 |
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Upgraded to a Flatbed Filter |
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Joined: 27 Jun 2008, 21:27 Posts: 147
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gsi8v
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Posted: 20 May 2019, 20:13 |
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Upgraded to a Flatbed Filter |
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Joined: 27 Jun 2008, 21:27 Posts: 147
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Corsa Addict wrote: Looks neat. Well done
Price range? You planning on mass production? I sold this set up for R750. The airbox and filter was laying around in my garage and I wanted to make the most of my money back from the filter. I'm not looking to mass produce this one, I but I do have a cold air intake system design for Corsa B 1.6 that I could look at mass producing. I'll post some pics the moment I have a final design. This is post is show my workmanship and design theory I apply when it comes to improving air velocity speed and density for anyone who is looking for someone to build or improve an intake system.
_________________ 2002 Opel Corsa Gsi ltd 1.6 Custom cold air induction system Polished throttle body (53mm) OEM exhaust manifold 50mm stainless steel straight through exhaust system Smash & grab tint Webasto tilt and slide (factory fitted) Style inspired by Opel Motorsports
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Corsa Addict
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Posted: 21 May 2019, 09:38 |
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Joined: 29 May 2007, 13:54 Posts: 49707 Location: Paarl...ex Durbs
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_________________ Opel Club Cape Town Member
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DJ7
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Posted: 24 May 2019, 10:06 |
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Joined: 07 Aug 2008, 13:00 Posts: 7799 Location: just cruising...
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Would be interesting to see dyno results on the same day with the same car and using this and the standard stuff.
_________________ Current: '05 VW Golf 5 2.0 TDI Sportline '97 VW Jetta VR6 '83 Datsun 1400 Sunny Ex: '97 Opel Astra Estate 200i '00 Opel Corsa GSI 2.0 16v '96 Opel Astra 200i E 16v '02 Opel Corsa GSI 1.6 '93 Honda Ballade 160e 16v '95 Opel Astra 200i E 16v
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gsi8v
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Posted: 25 May 2019, 11:40 |
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Upgraded to a Flatbed Filter |
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Joined: 27 Jun 2008, 21:27 Posts: 147
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There wouldn't be much of a difference in the kw curve because the throttle still only let's in so much air. There should be a difference in the torque curve as air will flow faster in to the cylinders, increasing acceleration.
But it would be interesting to see what difference this set up would make on a dyno.
_________________ 2002 Opel Corsa Gsi ltd 1.6 Custom cold air induction system Polished throttle body (53mm) OEM exhaust manifold 50mm stainless steel straight through exhaust system Smash & grab tint Webasto tilt and slide (factory fitted) Style inspired by Opel Motorsports
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gsi8v
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Posted: 25 May 2019, 11:57 |
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Upgraded to a Flatbed Filter |
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Joined: 27 Jun 2008, 21:27 Posts: 147
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And as with all great designs.... It's starts with a drawing!
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PSX_20190525_115318.jpg [ 259.61 KiB | Viewed 5920 times ]
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_________________ 2002 Opel Corsa Gsi ltd 1.6 Custom cold air induction system Polished throttle body (53mm) OEM exhaust manifold 50mm stainless steel straight through exhaust system Smash & grab tint Webasto tilt and slide (factory fitted) Style inspired by Opel Motorsports
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