Ultimate A3 Intake

[schwartza3]

Hey guys, i recently fitted some 380cc injectors and VR6 maf housing, running the VR6 maf meant the stock air box no longer fit.
I hate the noise of open filter so I decided to build a custom intake/airbox, starting from the bottom of the bumper. I’ll let the pics do the talking. It took a lot of modeling with carboard, once I got it right, start fabing it up. Terrible at progress photos, but you get the idea.












Fitted on the car, the plastic part after the scoop is from a beemer, the outlet is 3.5inch and is the biggest that can fit through the opening next to the battery.






Since the A3 bottom of the bumper is restrictive, I decided to open it up a bit.
The bottom part of the bumper is flimsy plastic so to avoid cutting of bits any further, I folded them over inside and plastic welded the cut edge.







This was before I finished sanding.
I prob should have used a bit of filler to smooth it out further





Fitted on the car




Seemed a bit too open so installed some mesh on the bottom & repainted.
Looks a bit like RS type bumper, came out ok I guess.





So after having a better look at the front bar decided to build one from the front as well just like 2L TSI cars, although I borrowed the idea of a scoop from BMW. I’m sure designers intended this opening to be the intake on 1.8t cars like on 2L TSI, anyway here are the pics





Some more modeling





Opened up the front grill a bit as well for better flow





Painted and installed the scoop.











Started fabing up the rest of the intake after the scoop.








Took my time with this one since its in the engine bay.
Made some other custom parts to bolt to this








All done, painted with some black wrinkle paint





Installed in the engine bay, used all existing holes to mount the intake. No drilling needed. Ignore auto meter sticker








Pipe to be finished and painted, just making sure it all fits good





Model air box, haven't done the pipe from the front intake at the bottom of the bumper yet.





S2000 stock air filter, idea borrowed from you guys here!





Just started the air box.
Made a mounting point for the final stage ignition, trying to keep the location as stock as possible.




still need to cut out the opening on the right hand side of the box for the pipe from the bottom intake (behind the bumper) and finish off the cover.







I'll update the rest as I go and let you all know if it makes any difference haha
should be ok, every little bit counts

 

[s3_trev]

Fantastic bit of fabrication there mate!

 

[s3 Hoggy]

brilliant mate!

 

[VAG-Slag]

Nice, I like it... Possibly a little over kill but I like it! Good work mate :thumbsup:

 

[Tricky20vt]

Like this a lot!

 

[s3dave]

Great Attention to detail...:icon_thumright:

 

[Westy]

I love new ideas especially when they're DIY. Good man :thumbsup:

 

[s33nyboy12]

Very imaginative and clever idea....be interesting to see if it shows real life gains ?.? Thumbs up

Sean

 

[Miguel_S#]

very interesting, very good

 

[badger5]

good work dude

 

[MIGGZ]

WOW!!!!!! this is some insane work! keen to see final outcome

 

[schwartza3]

Thanks for the comments guys, I'm really glad you all like it.
I'm just working on the cover at the moment, I know it looks fairly straight forward but the shape is a bit tricky to get.
I'll update as I go, thanks again!

 

[Chlippo]

Respect!

 

[schwartza3]

Hey guys, just sorting out the fitment, making sure nothing rubs, trimmed top of the airbox just a little bit and came up with a better solution how to bring the bottom pipe in past the battery into the box, sorry no pics yet. Test drove it and to be honest it feels like the intake at the top would have been sufficient, anyway can't hurt to have another one. Here are some pics of the set up so far.

 

[S3 Paul]

This is some very very high quality fabrication !
Well done

 

[Nilz]

Looks good and hats off for the time and effort you are putting in!!!

 

[MIGGZ]

keen on the logs to see the difference but an amazing job!

dont suppose you have a build thread of your car?

 

[Nick_sheep]

Nice bit of fabrication. Awesome looking car too.

 

[Munch]

I seriously need to learn how to weld!! Always a huge fan of someone brave / clever enough to try something different!

 

[schwartza3]

Thanks for the comments guys.
I'll need to get my vagcom working again, should be able to do a couple of runs to see the difference.
Sorry Miggz, no proper build thread, I do have a pic thread over at vwwatercooled.ogr.au
Munch, no welding involved here, just a bit of precision. Anyone with a bit of patience could do this, as Westy mentioned this is definitely a DIY.

 

[Mi11ar]

wow very impressive how much for one of my own!?

 

[fanta]

I like this, but isn't there enough air coming from the wing?

 

[Munch]

Thanks for the comments guys.
I'll need to get my vagcom working again, should be able to do a couple of runs to see the difference.
Sorry Miggz, no proper build thread, I do have a pic thread over at vwwatercooled.ogr.au
Munch, no welding involved here, just a bit of precision. Anyone with a bit of patience could do this, as Westy mentioned this is definitely a DIY.

How is it held together then? Pop rivets? Shall definitely be looking into getting some sheet metal and cardboard to make some bits

 

[MIGGZ]

Thanks for the comments guys.
I'll need to get my vagcom working again, should be able to do a couple of runs to see the difference.
Sorry Miggz, no proper build thread, I do have a pic thread over at vwwatercooled.ogr.au
Munch, no welding involved here, just a bit of precision. Anyone with a bit of patience could do this, as Westy mentioned this is definitely a DIY.

could you maybe share a link of said pictures please. sorry for the trouble just really love your car

 

[MIGGZ]

Thanks for the comments guys.
I'll need to get my vagcom working again, should be able to do a couple of runs to see the difference.
Sorry Miggz, no proper build thread, I do have a pic thread over at vwwatercooled.ogr.au
Munch, no welding involved here, just a bit of precision. Anyone with a bit of patience could do this, as Westy mentioned this is definitely a DIY.

could you maybe share a link of said pictures please. sorry for the trouble just really love your car

 

[Neru]

could you maybe share a link of said pictures please. sorry for the trouble just really love your car

this car was inspiration for me when I first bought my a3 4 years ago, Still my favorite 8L

 

[schwartza3]

this car was inspiration for me when I first bought my a3 4 years ago, Still my favorite 8L

Thanks Neru! my build is nowhere near what you've done with yours though.
Here is the link Miggz: Few pics of my mk1 - Page 12
Munch, it's all held by pop rivets, just cut/bend precisely so you only need a few rivets to hold it together.
Fanta, I'm sure there is enough air coming from the wing/under bonnet, as i said in my first post I mainly did this to reduce the induction noise by enclosing the filter, hopefully it improves the air flow to the filter along the way.
Finished the opening for the pipe for the bottom intake, will some post some pics later.

 

[MIGGZ]

Thanks dude that epic, love the lower lip and roof racks wana see how you did the lower vents

 

[schwartza3]

thanks Miggz
just been finishing off the air box, its getting there.
i'll need to get different profile rubber seal for the cover and a different one for the new opening.
Just tried out the rubber seals i had at home and they weren't good enough

 

[schwartza3]

ok, so I finally decided to finish this off......here are the pics of the finished product.

















Inside the box




I'll snap a few photos of the engine bay, everything fits great, car drives great, it's now legal and most importantly the induction noise has been reduced.

 

[Prawn]

That looks amazing!

Apologies if I've missed it earlier in the thread, but what was previously not legal about the open cone?

 

[Rainbird]

I'm assuming it's simply due to the tight restrictions on modifications in Australia, Nick.

Great bit of fab work as has already been said in here countless times. Really high quality of finish! Fingers crossed for decent results on the logging front too

 

[badger5]

nice work. now fit a better higher flowing filter ... S2000 is cheap, its not the best flowing. Shame to skimp out on the great work you've done on fabricating the rest of it

 

[VAG-Slag]

So perfect, epic work dude... Can't wait to see it in!

That looks amazing!

Apologies if I've missed it earlier in the thread, but what was previously not legal about the open cone?

It's simply cos he doesn't like the sound of an open cone Nick... That's some dedication there though!

 

[Alex C]

It's simply cos he doesn't like the sound of an open cone Nick...

...it's now legal

Australia is pretty hard on modifications I think

 

[VAG-Slag]

Australia is pretty hard on modifications I think

yea I know, I lived there for 2 years... An open cone should be fine though

 

[Prawn]

nice work. now fit a better higher flowing filter ... S2000 is cheap, its not the best flowing. Shame to skimp out on the great work you've done on fabricating the rest of it

Are you finding these a bit hit and miss lately Bill?

Mine gave no restriction at all at 370bhp, with no power increase at all when it was removed to test, yet Daz's seemed to struggle at just ~300.

 

[badger5]

s2000 could be many things

those we've removed and replaced with JR have all made more power with JR

go figure

lets face it some folks are buying cheap as you like filters.. What do they expect ***

 

[Jenno007]

yea I know, I lived there for 2 years... An open cone should be fine though

You need a mod permit to run an open cone in Australia, and it has to be secured.

I plan on making an air box for mine but nothing at this level! This is amazing!

 

[IPG]

So are you taking orders???