heinzboehmer's 2002 Topaz 6MT Coupe

[0-60motorsports]

Amazing work yet again brother.

[heinzboehmer]

Okay, some more progress on the cabin air filter housing.

I was dead set on not adding any material to the firewall plug (only making clerance for the braces), since that part is already kinda tricky to install. Figured any extra features would only make it worse. However, this put me at a point where I was fighting for fractions of a mm on the housing to find a compromise between space for the filters, clearance for the braces, clearance for the wiper linkage and clearance for install/removal.

Eventually, I realized this made up constraint was negatively impacting the usability of these pieces, so I decided to transfer two small features onto the firewall plug. Yes, this means I need to reprint what I already have, but oh well.

Here's my test fit prototypes, attached with the most professional of methods:



In place:



Moving those two bumps to the firewall plug means I have miiiles of clearance for installing the filter housing. The middle tab on the windshield cowl does slightly interfere if you try to just lower the housing on, but tilting it up lines the tab up perfectly with the bore for the middle fastener, so it all works out!




And here's a quick screenshot of the assembly in CAD:



You can see I still need to model in all the sealing surfaces on the filter housing, but the overall geometry of the two pieces is feeling pretty final at this point.

Honestly not thrilled about the amount of sealing surfaces I've had to add, but I guess that's what you get when your design interferes with EVERYTHING.

[heinzboehmer]

Oh shoot! I bought some cheap amazon conduit as well. I'll keep a lookout. Glad you got the car up and running so quick!

Probably will show up to the Menlo Park meet this Sat if you're around.

Well, you know where to find me if you ever find it melted in your engine bay

Unfortunately have plans on Sat, so won't be able to make it. Next time!

I can buy off some of you. If we meet Thursday for the 3D prints?

More than welcome to have some of it for free. Would rather you buy me coffee or something next time we see each other. The entire 100ft spool was about $30, so feels dumbs to charge for a few feet of it

[maupineda]

When I had the intake off last week, I noticed that the harness I recently built for the MAP + IAT looked like this:



Guess the conduit I used wasn't exactly rated for high temps. So I did some looking around and ended up ordering some 1/4" ID Drossbach 014NDBUG. Looks pretty much identical to the BMW stuff and is made of high temp nylon rated to 150 C.

Conduit and remaining idle hose (top) swapped out:



Now all I need to do is figure out what to do with the 98ft of conduit that I have left over:



Yeeaah, I probably should have stopped to think what 100ft of conduit actually meant before just blindly accepting that as a minimum order quantity...

I can buy off some of you. If we meet Thursday for the 3D prints?

[bavarian3]

Oh shoot! I bought some cheap amazon conduit as well. I'll keep a lookout. Glad you got the car up and running so quick!

Probably will show up to the Menlo Park meet this Sat if you're around.

[heinzboehmer]

When I had the intake off last week, I noticed that the harness I recently built for the MAP + IAT looked like this:



Guess the conduit I used wasn't exactly rated for high temps. So I did some looking around and ended up ordering some 1/4" ID Drossbach 014NDBUG. Looks pretty much identical to the BMW stuff and is made of high temp nylon rated to 150 C.

Conduit and remaining idle hose (top) swapped out:



Now all I need to do is figure out what to do with the 98ft of conduit that I have left over:



Yeeaah, I probably should have stopped to think what 100ft of conduit actually meant before just blindly accepting that as a minimum order quantity...

[Arclitgold]

Great work! The little rattles drive a man insane. It’s weird that hose isn’t available anywhere.

[heinzboehmer]

Grabbed this thing to run errands for a couple hours today. No codes, no limp mode. Nice.

[heinzboehmer]

Most parts arrived:



The top hose for the ICV has a lead time, so that's arriving later. Also, I broke the door lock button on the hazard switch when cleaning the car up after that off track adventure, hence the new one on the bench.

Old hose put up a bit of a fight coming off:



Nothing a plastic scraper and some patience couldn't take care off though:



And done:



Also, I found the oil drain line disconnected from the airbox, sigh. Guess replacing the line wasn't a real fix.

Decided I had had enough of it, so busted out the dremel and hacked away at the aluminum boss on the airbox.

First, cut some clearance into the sides of it (tape is only there as a reference for the cut line):




Next, I trimmed back the lip on the inside of the two tabs:



Not as pretty as what came from Karbonius, but the hose actually clips in now!



And with that, car is back on the road!

Unsurprisingly, fixing the vacuum leak improved drivability. Leak was small, so the difference isn't enormous, but it's definitely noticeable at small relative openings.

Just to drive the point home, here are the adaptations before:



And here they are after the fixes, a reset and ~30 min of normal driving:



Good stuff.

[heinzboehmer]

I was going to say you're overthinking this but I remembered what thread I was in...hahahaha

Lol, overthinking and overengineering are my signature strategies!

[bigjae46]

Printed a TPU test piece in the same dimensions as the -16AN hose, and it fits perfect. It's pretty much exactly the same as what's on there now.

Unfortunately, I just cannot find a -16AN hose that has the internal Viton liner. The Raceflux stuff above only goes up to -12AN, unfortunately. There's lots of -16AN PTFE lined hose available, which is likely better, but all of it is white...

So, I caved and bought the BMW stuff. Don't want to delay getting the car back on the road just cause I'm being stubborn.

I was going to say you're overthinking this but I remembered what thread I was in...hahahaha

[heinzboehmer]

Printed a TPU test piece in the same dimensions as the -16AN hose, and it fits perfect. It's pretty much exactly the same as what's on there now.

Unfortunately, I just cannot find a -16AN hose that has the internal Viton liner. The Raceflux stuff above only goes up to -12AN, unfortunately. There's lots of -16AN PTFE lined hose available, which is likely better, but all of it is white...

So, I caved and bought the BMW stuff. Don't want to delay getting the car back on the road just cause I'm being stubborn.

[heinzboehmer]

Hate to say but 50 is not much when you consider the downtime, I'd buy the stock hose unless you can quickly find a source, sometimes these type of things just don't exist in the open market, unless you source by dimension and not care much about the very same spec, and just change it every now and then I guess.

Yeeeah, I'm slowly starting to realize this. There are no good consumer sources for the hose, unfortunately.

The only lead I have is that -16AN hose is almost the exact same dimensions. There seem to be some companies that produce what I want, albeit with a couple extra layers that I would have to remove. e.g.:



I have yet to find someone that sells an FKM/ECO/whatever hose in -16AN size, though. I'll keep looking, but it's totally possible that I'll need to give in and just buy the BMW stuff.

[maupineda]

Hate to say but 50 is not much when you consider the downtime, I'd buy the stock hose unless you can quickly find a source, sometimes these type of things just don't exist in the open market, unless you source by dimension and not care much about the very same spec, and just change it every now and then I guess.

[Obioban]

If you have to buy a longer section, I’ll buy some off you