Intake work UPDATE

Duster · #1 (**permalink**) 07-30-2010, 05:49 AM

Well I have had some time to think about things and piddle around.
While doing so, I came to realize something...

Regardless of what any of us thinks, k&n type filters (oiled cotton) is way more readily accepted than oiled foam in the KFX community. So rather than play solely on my own preferences, I decided to open my eyes to both and see what I could do in my work with both style elements... and see what I could do different or better.

I think you guys are going to be really impressed with what I have done, particularly with the k&n style filter setup.

I have done some things different than FCI, K&N and Fuel ATV.
And I believe it is going to top the others and be a contender for FCI.
Garrett's tube is a nice piece of work though and huge... so it will be interesting...

What I have done is... a lot of studying on air intake mostly...

What I put together is, a 6x6.5 k&n style filter that can flow enough air for a V-8 engine, that incorporates an internal 6"-to-3" velocity stack feeding into the 3" internals of the LTR tube.... and I have done away with pumping the hot crankcase gases into the intake all together.

I'll report back with pictures and my preliminary guestimates as soon as I get my mapping a little more dialed in.

skitzo433 · #2 (**permalink**) 07-30-2010, 02:39 PM

Good to hear that your still working on your design. I'm still playing with my intake also. I also just got done with my flow bench!!! I've been comparing Uni foam filters to K&N filters. All tests were done using filters for a 06-09 trx450r, this is the filter I'm using on my KFX.
I've found that a K&N will flow more air than a Uni when each are clean and properly oiled. However the K&N does not filter air nearly as well. Also as the K&N gets dirty, it really loses air flow quick. As the pleats get dirty, the dirt, fine dust and sand begin to accumulate and the filter will begin to loose surface area.
This weekend I'm going to run the k&n with an outerwear to see if that helps with the filtration and accumulation of debris.

keep up the good work

georgiakfx · #3 (**permalink**) 07-30-2010, 02:44 PM

Duster- that filter sounds massive, I'm ready to see how you fit it in the kfx

Duster · #4 (**permalink**) 07-30-2010, 05:30 PM

Quote: Originally Posted by georgiakfx

Duster- that filter sounds massive, I'm ready to see how you fit it in the kfx

Yep... that is the pain of my existence at the moment...

It fits fine as an airbox eliminator... but doing the box setup I want is a challenge. If I can get it to work, I believe this will be the largest filter that it is possible to fit... (inside a real box & without trimming plastic).

Duster · #5 (**permalink**) 07-30-2010, 05:35 PM

Quote: Originally Posted by skitzo433

Good to hear that your still working on your design. I'm still playing with my intake also. I also just got done with my flow bench!!! I've been comparing Uni foam filters to K&N filters. All tests were done using filters for a 06-09 trx450r, this is the filter I'm using on my KFX.
I've found that a K&N will flow more air than a Uni when each are clean and properly oiled. However the K&N does not filter air nearly as well. Also as the K&N gets dirty, it really loses air flow quick. As the pleats get dirty, the dirt, fine dust and sand begin to accumulate and the filter will begin to loose surface area.
This weekend I'm going to run the k&n with an outerwear to see if that helps with the filtration and accumulation of debris.

keep up the good work

Wish I had a flow bench to mess with and do testing...

Duster · #6 (**permalink**) 07-31-2010, 05:56 AM

Well boys, I tell you what... I've come up on some surprises...

#1- It's unreal how much vibration is transmitted to the intake system.
#2- I've certainly done something right because it runs stronger with this intake setup than it does with the LTR tube and no filter, and stronger than it does with no intake at all.
(yep couple accidents)

This setup has actually gotten me a lot more excited than I expected. To be honest, I was really rather unimpressed with the LTR tube + K&N when I tested that. I had modded my stock intake setup to the point I really couldn't tell any difference besides the intake noise.

But this I am working on now impresses me. So much so that I am already honing on it for improvements and working on a way to for certain make it work... which means I start over on the box working up a new one, and may possibly have to trim plastics, which I have been trying to avoid.

So far in honing and tuning this intake up, I decided to take a little gamble and start playing with tuned length a little. I started by shortening up a flange by a 1/2". That was favorable so I trimmed another 3/8". That was favorable also... so... now I have taken a larger risk and shortened the other flange 1/2"... and actually shortened the LTR tube about 1/2" also.

Can't wait to try this!!!

My theory has been that the LTR450 is pretty well done on the intake tract and runs pretty happy despite a tiny air box and filter with only the LTR tube for tract length... and doing a simple filter upgrade is worth 3 HP+ on the LTR.

Same concept applied to the KFX plus some... so the shortening I have done helps to compensate for the KFX throttle body boot length, and at the same time also gives me more room for more box and more filter!!!

jbfoco · #7 (**permalink**) 07-31-2010, 01:17 PM

Sounds like ur having fun with it! Keep it up and let us know what u learn

Duster · #8 (**permalink**) 08-02-2010, 05:42 AM

OK.... I have made the whole deal work!!!!

The only semi-unexpected thing that came about in the process is that as it stands now, the rear plastics will have to come off to install it (6 bolts involved) unless I figure out something and make some changes.

The reason is that the forward part of the subframe tapers in narrower PLUS the plastic lines run at an angle \ at the rear of the box. And the box came out so long on the bottom that the thing won't fit down in there.

So choices are...

Rear plastic comes off for install.

It's going to have to come up from the bottom and bolt through the side of the subframe.

Or I get more creative with the geometry of the bottom of the box until it fits.
(might be able to angle the bottom corners like... \side view/ ...and get it to slide down)

Not sure which route to go...

skitzo433 · #9 (**permalink**) 08-02-2010, 12:52 PM

How about some pics? You have been looking at this your self. Maybe a fresh set of eyes can give a suggestion that you may have over looked. I know it has helped me when building total custom builds.

Duster · #10 (**permalink**) 08-02-2010, 05:39 PM

Ahh... I have failed to take any pictures of the box work so far...

I am going to mess with it now to see what I can figure out.

I looked lastnight and the plastic removal is no biggie anyways.

Bolting to the subframe sucks though.
I recall that from removing the stocker...exhaust is there on the right side to contend with.

I am going to see what I will have to change on the shape for a slide in.
If I don't like it I am just going to leave it be and pop off the rear plastic.
It's only a few bolts and no plastic trimming or anything is involved.