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Discussion Starter · #1 · (Edited)
I just wanted to post a background on these units and how they are being made so if people are interested in them, they can purchase one for their car.

When we got our VTurbo, it was so new that pretty much nothing was available and I knew that I wanted to make a SRI for the car or even a CAI.

Originally, I had made a SRI (Short Ram Intake) just for some ummph in the noise department but when I saw the power results of Injen's CAI vs. the SRI, I decided to make an extension for a full CAI.

I haven't been do the dyno yet and won't have a stock baseline to compare it to but I think you can sorta feel the difference between the stock snorkel intake and the SRI. I haven't had the CAI long enough to comment.


I would like to think that this intake will perform very close to the Injen system as far as performance goes. There is not much of a design difference between the two.

Design:

The piping is aluminum and has a 2mm thick wall which means it is very strong. I chose this piping carefully when I was building turbo systems because it wouldn't crush when tightening couplers like some cheaper piping.

The couplers are 3-4 ply silicone which means they are everything and more than you would need for an intake system. They hold up well to heat and clean very easily (unlike some rubber couplers)

The hose clamps are Stainless Steel T-bolt style. This means a few things. They have more clamping pressure than worm groove clamps, because they are wider. They also will not tear into your couplers like worm groove clamps can. They also look much nicer.


Build:

I am cutting all the piping by hand and cleaning up the edges to ensure there are no burrs that could possibly be sucked into the system. For buyers, you will not need to do anything but remove the stock system and have a couple tools for the install.

The cutting method I am using is a pipe cutter from harbor freight. This method will introduce a little scuff on the pipe where the rollers touch it. Not to worry though, as the couplers cover the scuff! The rest will look just like the piping in the pictures.


IMPORTANT:

This system does NOT recirculate the bypass valve to the intake, so you will need to leave it disconnected or remove the hose. This will not cause ANY issues with how the car functions or pose any problems. The only difference is that your BPV will now vent to the atmosphere and be a bit louder. It will function as a BOV.

Also, this system does not route the valve breather back into the system as that would introduce blowby/oily substance into the system. You can run a breather filter on your valve cover, vent it to the atmosphere or run a catch can. A catch can will be the most environmentally friendly option. I have mine dumping to the atmosphere right now.

If you really want to route the breather back to the system, I can install a fitting on the CAI/SRI for 10$. The reason I don't include this fitting is to keep the cost down and prevent the chance of blow by gumming up the intake side of the head


Here is the SRI setup:




Here is the CAI setup: ( I will get better pictures of the CAI setup soon, these were taken at night)





I am pretty positive this will be the best bang for the buck on a CAI or SRI system for this car.

The biggest difference in the CAI I have observed is it is a bit quieter than the SRI because the tubing is longer and it is located in the fender well. The Injen dyno's show a significant improvement going from the SRI to the CAI thought (5 peak hp). Since the design of this system is VERY close to that of the Injen, I would assume similar gains.

What is included:



Pricing will be as follows and include shipping to the lower 48 continental US states:

SRI (with filter) : 120$ shipped
SRI (without filter - you will need to buy your own) : 105$ shipped
CAI (with filter) : 140$ shipped
CAI (without filter - you will need to buy your own) : 125$ shipped

Optional breather fitting: 10$ (See above in 'IMPORTANT' section)


If you are interested in buying, my paypal is [email protected].

It will be around 2 weeks from your order date until you can expect it in your hands as I will be building these on an order-by-order basis!
 

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Discussion Starter · #2 · (Edited)
On a scale of: "I don't know what a wrench is-1" to "I can build a motor in my garage-10", I would say this is about a 3 for the CAI and a 2 for the SRI. The SRI is easier because you don't have to remove the bumper at all but the bumper removal/stock intake system removal is very easy.

The only part that some people may not like doing is removing the stock intake system, which requires removal of the bumper and a bunch of bolts/screws. Removing the stock intake system requires a phillips head screwdriver and a 10mm socket.

The entire job for the CAI system should take around one hour or so for someone who knows their way around tools. Maybe an hour and a half for someone doing this type of work for the first time.

This is not a job that I would be afraid to tackle if I was a beginner. I am always around to answer questions!
 

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Discussion Starter · #3 ·
I would just do it without the fitting personally. It isn't going to make a huge difference either way though. If you are concerned about the environment, get the fitting. If you aren't to concerned with build up over time that may or may not have a significant effect, go with the fitting.

Main reason for not including it is to keep costs down for everyone but there is the option to add it in.

The catch can on the PCV is going to help with the oil blow by also. If you cut off the breathers source to introduce blow by into the system it is easier than hooking a catch can to it and hooking it back up to the intake.
 

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Discussion Starter · #4 ·
just bumping to update new thread location :p
 

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Can I ask a question that may be out of ignorance more than anything. It appears that you/your supplier/however the pipes are being made etc. have the ability to put custom bends in the piping. So in the SRI why have the coupler in the middle of the piping rather than one smoothly bent piece? I know it doesn't make a huge difference but I've always been under the impression that the absolute smoothest route with the fewest bends, couplers, etc. was best. Was it just easier to route that way?
 

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Discussion Starter · #6 ·
well, unless I were to have them do a custom one piece pipe and have a minimum order of 20 sets, it would be a no go.

A 45 degree bend in the intake piping is not going to significantly impact the flow as far as performance goes.

The kits are cut from bulk piping bends and it the only way to do it without a welder as far as I know.

Without a bracket like the Injen, the coupler helps keep the piping away from the radiator hose.

Hopefully I will be able to get some stock/SRI/CAI dynos to put the doubters to rest soon. Some people just like to over complicate things.
 

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well, unless I were to have them do a custom one piece pipe and have a minimum order of 20 sets, it would be a no go.

A 45 degree bend in the intake piping is not going to significantly impact the flow as far as performance goes.

The kits are cut from bulk piping bends and it the only way to do it without a welder as far as I know.

Without a bracket like the Injen, the coupler helps keep the piping away from the radiator hose.

Hopefully I will be able to get some stock/SRI/CAI dynos to put the doubters to rest soon. Some people just like to over complicate things.
Ahhhh, ok makes sense. Thanks.

Simple is good. I didn't even look at the injen to see that bracket so I never even thought about that honestly.
 

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Discussion Starter · #12 ·
thanks for the compliments on the CAI!! glad people are enjoying them!
 

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Not a deal breaker by any means, but did you have the chance to get to a dyno yet?

Also, any chance that he CAI can be installed without removing the bumper? Really don't like messing with the lines on body parts that are currently straight/even. :)
 

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Discussion Starter · #14 ·
haven't had a chance yet. Been to busy with the family, job, settling in from the move, etc.

The SRI doesn't require the bumper to be removed but it is a MUST for the CAI. The bumper is very easy to get back on and perfect :p
 

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haven't had a chance yet. Been to busy with the family, job, settling in from the move, etc.

The SRI doesn't require the bumper to be removed but it is a MUST for the CAI. The bumper is very easy to get back on and perfect :p
I definitely understand. I will be hitting you up for one of these some time in the near future... Thanks for developing some affordably priced products for these little cars!
 

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Discussion Starter · #17 ·
It would be best to spray it after the fact since it would get ruined when cutting the piping.
 

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Discussion Starter · #19 ·
Plastidip should work. I would probably use a high temp paint just to be sure it won't peel or crack. They make some really nice textured finishes that look great in my opinion.
 

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i just ordered a injen cai not realizing that its not even CARB legal .... any idea if they are going to try to make them carb??

man should jsut went to your turbo ><
 
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