Mr. 5 Style Intake - Zasquatch Style

Posted this long ago on bimmerpost, figured I'd bring it over here as well.

I wanted a Mr.5 style intake, but was not satisfied with the 3" flanges currently available on the market. Metal flanges were extremely difficult to find, most are plastic. The easiest to attain is the Spectre plastic flange, which looks insanely cheap and low quality to me. Even if a metal flange can be found, odds are it has very sharp corners and are less than aerodynamic.

For the above reasons, I chose to buy a section of 6061 Aluminum tube and have a friend of mine mill it down into a nice flange. Notice the chamfers on all inside edges, which should cut down on turbulence exiting the pipe.

Attachment 17258

I then used Silicone II household/RV/Auto gasket maker/sealant to affix the flange, as it has a very high temperature rating (400 deg F), is waterproof, grease and oil resistant, stays rubbery and will never crack.

Attachment 17259
Attachment 17260

For the filter, I chose the AFE 24-91016 with a 3.5" ID mounting, 6" base, 5.5" top, and is 5" tall. The second pic shows the CP-e pre filter I got free with one of my orders... A bit small for the filter I used, but it works :)

Attachment 17261
Attachment 17262

The adapter I made for the filter has a nice long chamfer, which mates up to the filter's inner curved transition quite nicely. In the future, I would not include the tapped holes for the bolts. When I did my final install, I learned that there is NOTHING to bolt anything to in that extremely tight space in the wheel well. Lesson learned.

Attachment 17263

Here is the whole system assembled. I ordered 4' of the flexible ducting from McMaster to be safe. I think my final version only uses about 2-2.5' though.

Attachment 17264

Overall the system works fantastic. I have not had to adjust anything, and couldn't be happier with my setup. I briefly considered either making a pipe or using silicone hoses to route the filter, but to be honest the flexible duct works very good.

For those wishing to fabricate your own flanges, here are the drawings I made:

Attachment 17265
Attachment 17266

I would be willing to design your own custom flange and provide drawings if you made it worth my time!

Unfortunately, my friend has no desire to mass produce these, he made mine as a favor - so please don't ask :(

Talk about attention to detail! :)

Loving the flange designs!

Very nice, I love that intake! I wish your friend was my friend lol.....

Quote:

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Originally Posted by Zasquatch

Posted this long ago on bimmerpost, figured I'd bring it over here as well.

I wanted a Mr.5 style intake, but was not satisfied with the 3" flanges currently available on the market. Metal flanges were extremely difficult to find, most are plastic. The easiest to attain is the Spectre plastic flange, which looks insanely cheap and low quality to me. Even if a metal flange can be found, odds are it has very sharp corners and are less than aerodynamic.

For the above reasons, I chose to buy a section of 6061 Aluminum tube and have a friend of mine mill it down into a nice flange. Notice the chamfers on all inside edges, which should cut down on turbulence exiting the pipe.

Attachment 17258

I then used Silicone II household/RV/Auto gasket maker/sealant to affix the flange, as it has a very high temperature rating (400 deg F), is waterproof, grease and oil resistant, stays rubbery and will never crack.

Attachment 17259
Attachment 17260

For the filter, I chose the AFE 24-91016 with a 3.5" ID mounting, 6" base, 5.5" top, and is 5" tall. The second pic shows the CP-e pre filter I got free with one of my orders... A bit small for the filter I used, but it works :)

Attachment 17261
Attachment 17262

The adapter I made for the filter has a nice long chamfer, which mates up to the filter's inner curved transition quite nicely. In the future, I would not include the tapped holes for the bolts. When I did my final install, I learned that there is NOTHING to bolt anything to in that extremely tight space in the wheel well. Lesson learned.

Attachment 17263

Here is the whole system assembled. I ordered 4' of the flexible ducting from McMaster to be safe. I think my final version only uses about 2-2.5' though.

Attachment 17264

Overall the system works fantastic. I have not had to adjust anything, and couldn't be happier with my setup. I briefly considered either making a pipe or using silicone hoses to route the filter, but to be honest the flexible duct works very good.

For those wishing to fabricate your own flanges, here are the drawings I made:

Attachment 17265
Attachment 17266

I would be willing to design your own custom flange and provide drawings if you made it worth my time!

Unfortunately, my friend has no desire to mass produce these, he made mine as a favor - so please don't ask :(

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Great post, +rep for you.

Thanks guys. I was tempted to buy a benchtop lathe and crank these puppies out myself, but that shit ain't cheap!

You sir WIN! ;) Very very nice job there man

Quote:

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Originally Posted by Zasquatch

Thanks guys. I was tempted to buy a benchtop lathe and crank these puppies out myself, but that shit ain't cheap!

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Get yourself a harbor frieght chinese special. For this kinda stuff you dont need super tight tolerances.

This is good work! thanks for posting

Quote:

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Originally Posted by DBFIU

Get yourself a harbor frieght chinese special. For this kinda stuff you dont need super tight tolerances.

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Lol yeah, 1 out of 10 of their air fittings fit properly. And don't get me started on their transmission jacks....

@Zasquatch, can your friend approximate the amount of machining time this took? Will give everyone a good idea of the overall cost of the parts.

Wish I still had access to a machine shop, I would make them for people.

Quote:

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Originally Posted by ATP

@Zasquatch , can your friend approximate the amount of machining time this took? Will give everyone a good idea of the overall cost of the parts.

Wish I still had access to a machine shop, I would make them for people.

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Here's the fine print lol:

-I guess friend is an overstatement..... He is a coworker that I get along with but do not socialize with outside of work. So I don't have much leverage with him. If he was a good friend, I would force him to make more and feed him beers while he did it.

-It took him ~8 hours to do both pieces. The flange took 60% of the time. That being said.... His lathe was broken so he had to use his milling machine. As you can imagine, this makes the process much more difficult and MUCH more time consuming. On a lathe this job would be CAKE. I can't imagine it taking more than an hour or two to get it done. It is Aluminum after all.... and just one big turn-down and a few chamfers with low tolerance.

-Prior to convincing him to make my pieces, (he charged me about $35 in Aluminum stock for his own projects) I did check out emachineshop.com to get a quote. Since I only wanted one made, the price was high. They also factor in material cost (I paid $60 for a foot long section of 6061 tube from McMaster). The total was right around $300 - totally outrageous.

I think some people should take the drawing to a small local machine shop and ask for some estimates. I think the results will be much more reasonable.

Yea, on a lathe this should be a really easy. Not a chance I would do this on a Mill, way to much work. FWIW, a 6" section of solid rod is cheaper than the tubing but the machining is probably going to cancel that savings out.

I would def take this to a local place, just need to find one.

Well, I have a friend thats making it out of Ti for me for free so I wont have any monetary input for any members, sorry.

Quote:

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Originally Posted by ATP

Well, I have a friend thats making it out of Ti for me for free so I wont have any monetary input for any members, sorry.

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Ti???? Damn.... You HAVE to one up me, eh? LOL def. post picks when you get it!

Haha, will do. I priced out Ti on McMaster for giggles and its crazy how much it adds up. I just asked my friend if I could ship him some 6061 and if he could make it, he offered to make it from Ti for free. Apparently his compnay has a lot of scrap Ti laying around. I will for sure post pics when I get them. He asked if I wanted them polished too, I thought that was over kill haha.

Quote:

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Originally Posted by ATP

Haha, will do. I priced out Ti on McMaster for giggles and its crazy how much it adds up. I just asked my friend if I could ship him some 6061 and if he could make it, he offered to make it from Ti for free. Apparently his compnay has a lot of scrap Ti laying around. I will for sure post pics when I get them. He asked if I wanted them polished too, I thought that was over kill haha.

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Wow... now THAT is a a good friend :)

Quote:

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Originally Posted by ATP

Haha, will do. I priced out Ti on McMaster for giggles and its crazy how much it adds up. I just asked my friend if I could ship him some 6061 and if he could make it, he offered to make it from Ti for free. Apparently his compnay has a lot of scrap Ti laying around. I will for sure post pics when I get them. He asked if I wanted them polished too, I thought that was over kill haha.

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Can't wait to see the photos.

not a bad design there

That's really cool. I have a Stett CAI currently, I wonder if I can take that and use it in a setup like yours for a more Dinan like CAI.

Dont hate on harbor freight. Oh that rhymes.

No seriously you have to know how to shop there, some things are pure shit. But other things are great for the price, just gotta have experience buying from them.

A cheap lathe from them to turn a flange like that is perfect, you are pressing it into plastic, you dont need +/- 0.001" tolerances so the 250 dollar lathe will work just fine!

For the other guy, why the hell are you using Titanium!?

Quote:

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Originally Posted by DBFIU

Dont hate on harbor freight. Oh that rhymes.

No seriously you have to know how to shop there, some things are pure $#@!. But other things are great for the price, just gotta have experience buying from them.

A cheap lathe from them to turn a flange like that is perfect, you are pressing it into plastic, you dont need +/- 0.001" tolerances so the 250 dollar lathe will work just fine!

For the other guy, why the hell are you using Titanium!?

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Well, I was going to use it solely because it was free. However, my friend's company doesn't currently stock Ti in that large of a diamater so Al it is! Still getting it for free and Ti was way overkill so I am not complaining.

Quote:

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Originally Posted by ATP

Well, I was going to use it solely because it was free. However, my friend's company doesn't currently stock Ti in that large of a diamater so Al it is! Still getting it for free and Ti was way overkill so I am not complaining.

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BUMMER! $1k worth of machined Ti flanges for free would have been outrageously awesome. I guess Al will have to do :)

I have an M3 rep bumper arriving tomorrow and have some big plans for it (thank you whoever bumped my car in the parking lot, I wasn't expecting to get one so soon). While I don't care about retaining the brake cooling ducts because I don't race, and when you are going straight they just blow onto your tire anyway, I DO care about retaining the oil cooler duct.

I will be doing the fog delete, and I have these sitting on my dining room table now (51747900823/824):

Attachment 17497

I knew the larger one should bolt right up to the oil cooler (not sure if I keep the partial block-off plate that is on it), but was unsure where the driver's side duct ended up. ECS Tuning listed it as a brake duct, but the upward angle suggested otherwise. I did some digging and found out it is one of 3 inlets to the M3 intake box!

Attachment 17498

Since the filter for my intake sits behind the bumper sandwiched between the fog light and wheel well, I plan to use this duct as a cold air supply. An added bonus for me! And since the duct is designed for an intake, it has several bends and ridges to ward off water. I wont be hooking it up directly to the filter, but it should provide a large volume of fresh cool air to that otherwise hot cramped cavity :awesome:

Oh, the things I get excited about ..................................

very very cool!