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Drilled Air Box

Discussion in 'A3/S3 Forum (8L Chassis)' started by DJ_Troopa, Jan 27, 2010.

  1. Curt

    Curt Member

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    Hmmm, think I might attack my air box tomorrow and smooth it.... Cheers guys. I would like some more induction noise, but don't want an open filter on because of heat soak. Was looking at the Ram Air enclosed kits for £100 on fleaBay, but don't know if they're any good or not.
     
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  3. 1animal1

    1animal1 The Clar!! it mouves!!!
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    why bother? your airbox is already enclosed...it just needs a decent air feed that you wont be able to give it unless you fit an FMIC.....
     
  4. Westy

    Westy Double Dark Side! Diesel & 8P

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    Started to smooth my new airbox out today and it's a fair bit of hard work! Broke my only dremmel cutting tool just as I started to hack the top half of the airbox fins. The bottom bit is half done but I'm trying to do a first class job.

    As I have a spare airbox it means I don't have to rush the job, I'll try and finish the job next weekend and get some pics up.
     
  5. 1animal1

    1animal1 The Clar!! it mouves!!!
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    dooood, angle grinder is where its at.....took me less than an hour to grind them out and smooth it off, and its a good job ;)
     
  6. Westy

    Westy Double Dark Side! Diesel & 8P

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    I was sanding for 45 mins by hand and you can't even tell the fins were ever there.

    Did you do the top half of the box too tim?
     
  7. S3 HODGE

    S3 HODGE Brown passenger seat.

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    Sounds good Westle :)
     
  8. 1animal1

    1animal1 The Clar!! it mouves!!!
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    na mate...... i didnt think about that haha...... have you? are they more time consuming you reckon?
     
  9. Westy

    Westy Double Dark Side! Diesel & 8P

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    The top half will take a lot longer than the bottom have due to their being bloody plasic fins everywhere. I just started on the top half when my cutting blade snapped.

    Onece I've sand papered the thing flat I'm going to give it a quick wet and dry too, it'll be sooooo smooooooth :)

    I'll do a vagcom graph for before and after to see if there's any difference at all or if it's just a load of old ********.
     
  10. 1animal1

    1animal1 The Clar!! it mouves!!!
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    na that'll be good mate, keep hold of the results then you may be able to do a before and after 4 inch CAI once you've got the FMIC on..... looks like ive got yet another job to do, cant beleive i missed the lid!! just never crossed my mind
     
  11. Westy

    Westy Double Dark Side! Diesel & 8P

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    You can't do a half job mate! Haha
     
  12. S3 HODGE

    S3 HODGE Brown passenger seat.

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    Tim will be wanting to buy an Airbox lid after getting the angle grinder out :) haha.
     
  13. 1animal1

    1animal1 The Clar!! it mouves!!!
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    you have no faith sir ;)
     
  14. mike_plymouth

    mike_plymouth Member

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    i took mine out the other day and removed all the fins from top and bottom, also there are 2 plastic blades that are in the tubing which links the air box to the maf housing. i used a dremmel with a mini circular sanding attachment and it was pretty straight forward. Since putting it back together i myself have noticed the pulling of my car from stand still is a lot smoother, it used to have a dead spot and since doing this it seems to have been minimised loads. i would deff recommend doing the mod if u have a spare 40 mins.
     
  15. Westy

    Westy Double Dark Side! Diesel & 8P

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    I've spent all day (7 hours) sanding my airbox down. Here's the final finish:

    [​IMG]

    [​IMG]

    I spent so long on the bottom and you cant even see where the fins were any more because I got it super smooth. I got fed up with the top and only partially sanded it down because I was getting bored.

    After dinner i'm going to do a before and after VAGCOM run and I'll let you know if there's any difference in MAF readings and bhp/torque :)
     
  16. Westy

    Westy Double Dark Side! Diesel & 8P

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    Well here's the results:

    Normal airbox:

    BHP = 256
    LBFT torque = 266
    MAF = 191

    Smoothed Airbox:

    BHP = 258
    LBFT torque = 273
    MAF = 191

    Boost was at 22psi and as you can see from the following graph the actual boost with the smoothed airbox holds a lot longer than with the normal airbox.

    [​IMG]

    It was definitely worth the hard work with the following increases:

    2 BHP
    7 Torques
    Smoother and prolonged boost delivery
    I've also got a load of sound like an asmatic old man and I can hear the DV a lot more now.

    If anyone wants to have a crack at it but doesn't want to attack their own airbox my standard airbox is now for sale. PM me if your interested.
     
  17. kitpayne

    kitpayne Member

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    Good work!!!!

    Was that just smoothing the box or a panel filter aswell?
     
  18. Westy

    Westy Double Dark Side! Diesel & 8P

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    Yeah sorry I was meant to have mentioned that. I have a green cotton filter. Not bad gains from a few hours work. I'd love to borrow one of the £100+ induction kits that companies sell and see what sort of increase I get from that because I dont think it'll be much, if any better.
     
  19. kitpayne

    kitpayne Member

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    Which green cotton one did you buy. just the one for the S3? How does it mount inside the air box?
     
  20. Westy

    Westy Double Dark Side! Diesel & 8P

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    It's just a panel filter mate, it just goes in place of the standard one, nothing fancy.
     
  21. ALPINE

    ALPINE Yes its diesel, now cry u lost

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    thats nuts... its true all the little things make a difference. There is alot of people on here would not beleive that would work because if didnt come from "a performance specialist" and would cuss you. My little 1.8t ran a 156.9 on the rollers yesterday after cleaning my inlet manifold out, smoothing off the ridges and poshing it, Polsihed and smoothed TB with a small 1mm bore out front the edge of the TB. (basicly reduced ridge inside the rubber pipe thats clipped onto the TB) full service and a performance panel filter! i think for a 12 year old car thats outstanding!

    I will be taking my air box off tomorrw and attacing it!!
     
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  23. kitpayne

    kitpayne Member

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    Oh right thought it may have been an induction kit inside the air box. seen that done a few times!!
     
  24. Westy

    Westy Double Dark Side! Diesel & 8P

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    That's excellent mate. I used to do all this sort of thing with my old Renault 5 Turbo, smoothing the TB and drilling out the air/fuel jets in the carb then winding up the boost. Its all good fun and there is easy performance gains to be had for nothing except a bit of hard graft.

    No mate that's the beauty of this mod, it wont cost you anything.
     
  25. steviet

    steviet Member

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    Ive done this to my airbox to,looks like i need a green cotton filter for better gains tho.
     
  26. Westy

    Westy Double Dark Side! Diesel & 8P

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    If I ever set my hands on a standard paper filter I'll re-run my test and see what the differences are.
     
  27. 1animal1

    1animal1 The Clar!! it mouves!!!
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    ive just binned a 6 month old one... bugger

    had a look at the lid the other day when i replaced the filter..... whoah man, your too dedicated.... i cant be arsed to do them aswel!! the bottom were ones were far bigger, the lid will be a job if im ever super bored...good to see the results though matey :)
     
  28. Westy

    Westy Double Dark Side! Diesel & 8P

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    I found an easier way to do the top. Instead of using a dremmel I just used a pair of pliers and twisted all the fins off. A lot of them came off so cleanly that they didn't need much sanding at all.
     
  29. s3 Hoggy

    s3 Hoggy Whats going on???

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    Cool Ill be doing this next weekend

    Cheers Matt
     
  30. steviet

    steviet Member

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    What about polishing the inside to or something or is that just going a bit to far??..
     
  31. Westy

    Westy Double Dark Side! Diesel & 8P

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    Maybe a bit over kill mate but you will probably see a slight increase again. :)
     
  32. S3 HODGE

    S3 HODGE Brown passenger seat.

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    O yea Westle, I want my airbox back! lol.

    Looks good.
     
  33. Westy

    Westy Double Dark Side! Diesel & 8P

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    You can have the airbox back if I can have my finger tips back! All that sanding has taken them off.
     
  34. 1animal1

    1animal1 The Clar!! it mouves!!!
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    all those years of 'ulay'ing not paying off ;)
     
  35. Welly

    Welly VX220 SC Driver :)

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    Good work there mate, impressive stuff.....! :icon_thumright:
     
  36. Matt82

    Matt82 Active Member

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    brilliant thread. good to see people verifying the gains for these mods.

    you want the squared area of the inlet to match or be a shade larger than the outlet of the airbox.

    some testing was carried out on cgti. typically these airboxes have a venturi at the top. this is actually a restriction. remove the venturi and then bell mouth the hole thats left over

    de screen your maf too. ive seen that gain G/S on vagcom
     
  37. fran-s3

    fran-s3 Active Member
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    anyone got a spare airbox screw lol? I lost one of mine and Audi keep ordering me the wrong one whenever I order it v annoying!!!!!!
     
  38. Westy

    Westy Double Dark Side! Diesel & 8P

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    When my FMIC goes on I have a 4" pipe ready to fit as an intake :)
     
  39. 1animal1

    1animal1 The Clar!! it mouves!!!
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    four inches!!!?? is that gonna be enough????
     
  40. Westy

    Westy Double Dark Side! Diesel & 8P

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    Thats just girth mate, it's a metre long!
     
  41. 1animal1

    1animal1 The Clar!! it mouves!!!
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    impressive...... :)
     
  42. JS1500

    JS1500 Howdy

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    Haha, I was just about to ask the same thing!

    Wanted: Airbox screw!
     

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