[Simple5]

Warning: I am an Enthusiast and a DIY kind of guy. I have done this at my own risk and you should bear that in mind as well!

Having the n63 intake from ARM Motorsports throw a code on me and seeing what CReynolds did with his car gave me a great idea. You can see his DIY here to route flex tubes and cone filters to the front of the car, but I want to make an intake like the Mr. 5 intake from my n54 days.

Here is CReynolds DIY (thanks for sharing man) and I have started my mission to make a high flow panel filter...

CReynolds's DIY is here:

http://f10.5post.com/forums/showthread.php?t=1441680

My mission begins.

Materials:
-2 stock air filters from RockAuto (L and R) for $17.09 each
-UNI Universal Foam Filters Fine and Coarse $14.21 for coarse and $13.41 for fine
-Hardware Cloth (metal mesh) Home Depot (1/4in- 2ftx5ft) 6,3mm for $9.99

Tools:
Exacto Knife or Box Cutter
Garden Shears
Sharp Scissors

Total before Tax and Shipping: Around 80 bucks

DIY Part 1:

1) Take the stock panel filters and cut out the paper element but leave the orange gasket in place.
2) Make a template in the back of the filter where the paper element was. This will assist you in cutting and measuring the mesh and the foam filters.
3) Use your template to mark and cut the mesh and the foam.

I'm working on this a bit at a time.. part 2 will come soon!

Any questions/suggestions please let me know!

[Creynolds]

I tried this before but kept getting maf codes but if it works for you then he'll ya good write up cause anything that saves money for us bmw owners helps

[Simple5]

I plan on doing this along with your intake setup. Filtered one way and filtered the other. Instead of sealing the air box up. About other tips would be helpful!

[535_BiTurbo]

Originally Posted by Simple3

I plan on doing this along with your intake setup. Filtered one way and filtered the other. Instead of sealing the air box up. About other tips would be helpful!

Im confused....you're going to use 2 filters (one in front of radiator and the other in the airbox?

[535_BiTurbo]

Originally Posted by Creynolds

I tried this before but kept getting maf codes but if it works for you then he'll ya good write up cause anything that saves money for us bmw owners helps

What did you try?

[Simple5]

Originally Posted by 535_BiTurbo

Im confused....you're going to use 2 filters (one in front of radiator and the other in the airbox?

Google Mr. 5 335i n54 intake and I am trying to do this exact setup with the n63.

[535_BiTurbo]

Originally Posted by Simple3

Google Mr. 5 335i n54 intake and I am trying to do this exact setup with the n63.

He cut a hole in the airbox and created a second air intake stream, similar to Dinan's 550i intake.

You've removed the filter and replaced it with mesh, but it's going back inside the airbox so thats why Im confused.

[Simple5]

Originally Posted by 535_BiTurbo

He cut a hole in the airbox and created a second air intake stream, similar to Dinan's 550i intake.

You've removed the filter and replaced it with mesh, but it's going back inside the airbox so thats why Im confused.

I'm not done with it yet. The mesh is going to attach itself to the top of the filter and the foam will be glued onto the mesh to make a complete high performance foam filter.

Its a spin on Mr.5's intake.. I won't be drilling into anything.

In Mr.5's intake:
Stock Air Box- K&N Panel Filter
Attached to Air Box- Drilled in Flex tubing that runs to the front driver side fender well with a cone filter attached.

My intake:
Stock Air Box-A Custom Foam Panel Filter like BadBlack's
Attached to Air Box- The flex tubing with filters running into the grills. They will not be drilled because they will attach to the induction side of the stock air box by silicone couplers..

[535_BiTurbo]

Are you making a secondary hole in both air boxes and attaching the flex piping (similar to Dinans)?

[Simple5]

No, I put up the diagram that CReynolds posted. The Flex pipes replace the stock air ducts and the part where I circled is where the flex pipe attaches via silicone coupler. So no, no secondary holes. Dinan's design is CRAP cause it draws little to no extra air with those dinky ass filters. Also, their design requires you to drill into the SIDES of the airbox and also into the front end. With CReynold's approach you are using all the stock attachments etc

[535_BiTurbo]

Originally Posted by Simple3

No, I put up the diagram that CReynolds posted. The Flex pipes replace the stock air ducts and the part where I circled is where the flex pipe attaches via silicone coupler. So no, no secondary holes. Dinan's design is CRAP cause it draws little to no extra air with those dinky ass filters. Also, their design requires you to drill into the SIDES of the airbox and also into the front end. With CReynold's approach you are using all the stock attachments etc

Ah ok, so on your design, you are just adding the panel filter where as on CReynolds design, he removed the panel filter completely. And on badblack550s intake, he removed the airbox completely and replaced it with a U pipe.

[Simple5]

Originally Posted by 535_BiTurbo

Ah ok, so on your design, you are just adding the panel filter where as on CReynolds design, he removed the panel filter completely. And on badblack550s intake, he removed the airbox completely and replaced it with a U pipe.

Bingo, Bango, Bongo! After I finish the filters I will run with them for a day or so to test them. After that I will add on the flex pipes.

[535_BiTurbo]

Originally Posted by Simple3

Bingo, Bango, Bongo! After I finish the filters I will run with them for a day or so to test them. After that I will add on the flex pipes.

Interesting to see how it compares to the ARM intake design and also if you notice any power differences.

Do you you think there is a difference between using smoothing piping vs flex piping? It seems like flex piping would slow the air velocity down...

[Simple5]

Originally Posted by 535_BiTurbo

Interesting to see how it compares to the ARM intake design and also if you notice any power differences.

Do you you think there is a difference between using smoothing piping vs flex piping? It seems like flex piping would slow the air velocity down...

The air still has to go through the stock airbox and through my foam filters as well so any turbulence will be before it gets into the airbox. After that it should be smoothed out but with a larger air volume and in theory enough to give an extra kick in the pants but not enough to trigger a lean code.

Main thing is sound and I believe the filters sitting in the front grill will achieve that.

[Creynolds]

Originally Posted by Simple3

The air still has to go through the stock airbox and through my foam filters as well so any turbulence will be before it gets into the airbox. After that it should be smoothed out but with a larger air volume and in theory enough to give an extra kick in the pants but not enough to trigger a lean code.

Main thing is sound and I believe the filters sitting in the front grill will achieve that.

They will. My dumping of the DV is extremly noticeable. And especially in lower gears or revs

[535_BiTurbo]

Any updates?

[Simple5]

Originally Posted by 535_BiTurbo

Any updates?

Updates soon. Holiday has been a little demanding with work/family/etc...

[Simple5]

Okay, I finally got the time to finish these. I have been driving around with them for a day or so and I have noticed that the car feels slightly smoother and there is a slight bit of induction noise.

It has been 150+ miles (took a road trip with my buddy to pick some stuff up) and NO CELS. I've also opened up the airboxes and checked the filter's integrity and no signs of stress, fraying, or anything..

So, On with the show....

DIY Part 2 (and final part)

Additional Stuff you need:

4- JB Weld Clear Weld 4000- $4.89 each Walmart
1- Gorilla Glue Heat Gun Sticks- $3.97 Walmart
1- Uni Cleaning and Oiling kit- $20.95 Ebay

4) Cut the foam pieces out and put them aside.

5) Now you have to glue the mesh to the plastic part of the air filter. I used JB Weld Epoxy 4400 psi Clear Weld.

6) Line up the mesh onto the filter and place some weight onto it. Now while the mesh is weighted down use copious amounts of the epoxy and just layer it onto the mesh and the orange portions of the filter. Let the mesh/filters dry for an hour before you can work with them.

7) Once the epoxy has set you will find that the mesh is on there. Now the next part is to put the foam onto the mesh. This i s where you will be using the Heat Glue Gun. Put in a Gorilla glue stick, plug in the unit, and wait for 5 minutes before using.

8) Once the glue gun is heated up, lay the FINE (Black) foam piece down onto the mesh. Now lift up only one side at a time and lay down the glue (you cannot lay the glue down first and then put the filter on. It will dry too fast). Give it a few minutes to set.

9) When you have the fine foam layer onto the mesh now attach the coarse filter onto the fine filter the same way you did in step 8. Lay the coarse filter on top of the fine filter and heat glue the outer edges down.

10) I let everything settle overnight. The next day I sprayed the UNI oil onto the course portion only of the filter to trap particles and to minimize the chance of a CEL. But also, I will be coupling this with CReynold's intake setup very soon. Let the oil soak overnight. If you want you can spray the fine portion as well. I placed paper towels on the coarse side with some weight to catch any extra oil.

Total Cost of the Project: $120

If you guys have any questions please let me know!!

[535_BiTurbo]

basically your setup combined with CReynolds setup, you will have 4 air filters.

[Simple5]

Originally Posted by 535_BiTurbo

basically your setup combined with CReynolds setup, you will have 4 air filters.

Like the Dinan setup but with tons more airflow. Instead of using the stock paper element I'll be using these filters and instead of using dinky piping and dinky filters like the dinan I'll be using CReynolds setup... in realty, it's all for the sound and a little bump in power.

Also a good DIY for someone that wants performance filters instead of their stock ones.

[535_BiTurbo]

You realize Dinan has an Auxillary air source introduced on both air boxes and they add 2 additional filters to filter that air. How is it tons more flow if you are adding 2 filters in the same air pathway when you go CReyonolds route?

[Simple5]

Dinan uses those dinky filters and you drill into the stock airbox. Dinan also relies on the stock filters. You yourself said on CReynolds setup your car is breathing better and deeper because the piping is wider and the filters behind the grill are drawing in more air. More airflow means less restricted overall.

I just don't like the idea of the filters going out begins the grills without something between the filters and the MAF sensors. I picked the thinnest and less restrictive foam to use on my filters.

In the end you're getting an intake for sound. I've heard/seen the Dinans in person and they are NOT worth the $2800 they are asking for on their website. Engine eye candy? Very much so.