Feedback on a headlight intake, airbox & ducting

[Darbshaw]

I finally got to work on a project I've been putting off for a while. My car is a dedicated track car, and this is more of an intermediate/fun project until/if I decide to splurge on a CSL airbox.

My current setup is a K&N Filter with an aluminum pipe running to an ECS Silicone Elbow to the stock airbox. This was a cheap alternative to switch back from a velocity stack setup. I want to provide better heat shielding to this and a more direct air feed. I plan to use the headlight intake duct as the sole air feed for the engine. This frees up the ability to use the fog lights purely for brake ducting and ditching the kidney grill feed. This is likely net neutral in terms of weight, but allows me to close off the kidney grills and brake ducts as I start experimenting with cooling.

I was hoping for insight if anyone has done similar, and if the volume of airflow is too low for the S54. See the pictures attached for my work-in-progress airbox, which I am making for the filter. This will have an 88mm opening at the front that takes a tube as a direct feed from the headlight opening.

My expected benefits:

• Contained airbox with direct airflow feed, less heat soak
• Individual control of the kidney grill & brake duct openings without sacrificing intake air

Current fears:

• Too little airflow will be supplied through the headlight intake to properly feed the engine

Let me know your thoughts as I'd love some feedback on this!

[x Spades x]

I always felt like this mods should be made out of clear plastic like the headlight covers. Even better, modify the oem headlight cover to have a clear plastic high beam hole integration.

[Darbshaw]

I always felt like this mods should be made out of clear plastic like the headlight covers. Even better, modify the oem headlight cover to have a clear plastic high beam hole integration.

I'm not sure how the high beam hole would be able to fit. Im personally okay without the high beam. Although I'm still hesitant on a full headlight blank. but that makes me interested in how a clear would look. Might give that a shot

[heinzboehmer]

I'm not sure how the high beam hole would be able to fit. Im personally okay without the high beam. Although I'm still hesitant on a full headlight blank. but that makes me interested in how a clear would look. Might give that a shot

I see these at the track a lot: https://psdesignsglobal.com/product/...ight-duct-kit/
I've personally installed one (not for my car) and the fit was okay. Carbon piece was slightly too long and I had to force the headlight lens on a bit.

[Darbshaw]

I see these at the track a lot: https://psdesignsglobal.com/product/...ight-duct-kit/
I've personally installed one (not for my car) and the fit was okay. Carbon piece was slightly too long and I had to force the headlight lens on a bit.

Originally I was going to go this route, but I figure I'd try and put my printer to use. Even with the prototypes in PLA I'm less than $100 in on this project.

Did you do any sort of ducting to make the intake only feed from the headlight air source?

Once I can get the headlight cut and assembly done, I think I'll be able to better explain my concern about reducing overall airflow

[heinzboehmer]

Did you do any sort of ducting to make the intake only feed from the headlight air source?

Ah, unfortunately I only installed the duct into the headlight. Didn't actually put it on a car, so can't help with the ducting part.

Will be interesting to see what you come up with!

[bigjae46]

I have a dual duct in the foglight area - one for the brakes and the other for the intake. I also duct the headlight to the intake. It is a carbon blank with a naca duct riveted to it.

i feel like there is plenty of high pressure air.

[Darbshaw]

Made some progress today. Still some minor fitment and cutting of the feed tube needed to be done but it's looking like it'll serve the purpose.

I'm not sure about the lower headlight trim yet. This headlight duct isn't my model and I'm not a huge fan that they have it run lower than the headlight itself. One of these days I'll go and make my own.

[Darbshaw]

I have a dual duct in the foglight area - one for the brakes and the other for the intake. I also duct the headlight to the intake. It is a carbon blank with a naca duct riveted to it.

i feel like there is plenty of high pressure air.

That's good to know. I'll be interested to see how this acts with only one inlet source.

Any thoughts on an easy way to measure the difference of airflow? I have IAT wired to the car and will log this, but this wont give an exact measure.

Another thought is logging my wideband before and after, maybe watching for adaptations adjustment. I'm not sure if this is the information I'm looking for.

[heinzboehmer]

Any thoughts on an easy way to measure the difference of airflow? I have IAT wired to the car and will log this, but this wont give an exact measure.

Sacrifice the stock filter housing lid, cut the MAF + trumpet part off, modify your airbox to attach to what's left of stock (there's a couple of convenient screws on the trumpet), log MAF?

[bigjae46]

That's good to know. I'll be interested to see how this acts with only one inlet source.

Any thoughts on an easy way to measure the difference of airflow? I have IAT wired to the car and will log this, but this wont give an exact measure.

Another thought is logging my wideband before and after, maybe watching for adaptations adjustment. I'm not sure if this is the information I'm looking for.

You can use a pieto tube in front and behind with a manometer.

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[Darbshaw]

Sacrifice the stock filter housing lid, cut the MAF + trumpet part off, modify your airbox to attach to what's left of stock (there's a couple of convenient screws on the trumpet), log MAF?

Can the ECU run MAP, IAT, and MAF all at once? I wish I had the OG airbox tube, I bet this could replace my aluminum tube off the elbow. Worst case I can always make an adapter for the MAF and use send cut send to weld it onto the tube. The MAF would also need to be in direct airflow as well right? This is a big issue with my current design since most of my space is post filter, to get any sort of direct airflow.

[Darbshaw]

You can use a pieto tube in front and behind with a manometer.

Is this what you've been using for your aero testing? I like this, seems simple and effective. I haven't had the chance to dig on the product page, can this also export logged data?

[heinzboehmer]

Can the ECU run MAP, IAT, and MAF all at once? I wish I had the OG airbox tube, I bet this could replace my aluminum tube off the elbow. Worst case I can always make an adapter for the MAF and use send cut send to weld it onto the tube. The MAF would also need to be in direct airflow as well right? This is a big issue with my current design since most of my space is post filter, to get any sort of direct airflow.

Ah didn't realize you were running a MAP. DME can't do all of that (unless you write custom FW for it). Gotta choose between MAF FW (stock) or MAP FW (CSL).

MAF placement is a bit tricky. Needs clean air, appropriately sized volume, etc. Probably easier to just buy a used stock unit, they're fairly cheap: https://www.ebay.com/itm/325831237051

[bigjae46]

Is this what you've been using for your aero testing? I like this, seems simple and effective. I haven't had the chance to dig on the product page, can this also export logged data?

Yes. I do it caveman styler and use my in-car gopro to record the readings which is OK. I need to figure out something better. I'm not an electrical genius so would be great if someone could figure out a way. With that said, I can overlay the speed data and see the manometer reading as long as the lighting it right. I have gotten enough clear video to be useful.

I've only taken readings to test out the rig. I will do a baseline and then measure changes over the summer...possibly.

It does give useful data. For example, I do know that the gurney flaps in front of the hood vents adds about .3 in pressure differential at 120-ish MPH.