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2010 2011 BMW 5 Series Forum F10 F10 Technical Topics Engine, Transmission, Exhaust, Drivetrain, ECU Software Modifications Custom N55 air intake journey
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      09-05-2019, 11:39 PM   #1
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This is an experiment to see if I can make a decent air intake under 200 bucks. The mission is to increase time to spool and make a hybrid ram/cai intake. As we know the air ducts for the F10 N55 is a poor design from the standpoint of tuners like us. The intake starts by entering a 90-degree entry with no scoop, then takes a long path through the driver side around the hot engine bay and back down to yet another sharp turn into the turbo. If you're like me with a large fmic this makes for some horrible lag.

Since the F10 N55 shares the same body as the 550 and M5 there's another air entry passenger side that is much closer. I'm not sure why BMW decided against using that as the air intake entry for the N55 as it would seem it would've been cheaper in parts and added sportiness.

I'll be using a heat gun, some silicone couplers, black silicone adhesive, a U shaped plastic intake from a VW, and some spare N55 intake parts to dismantle and cut up. I'll be placing the same order of sensors and valve connectors and fusing them into the plastic.

Here's some preliminary photos. I'll be updating the thread as I make progress.
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Here is the updated progress on the fitting the fuel vent and crankcase valve:
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I never measured the exact circumstance so make the hole smaller then the crankcase fitting and carefully sandstone Dremel until you get a tight fit.
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You have to very carefully Dremel underneath the lip. I used a small cutting Dremel tool and shaved it very carefully.
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This is a 3/4" drill bit. You do not have to Dremel the hole afterwards as this is a perfect fit.
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Warning: I am getting air plausibility errors. It will have to be tuned out.
101F01 Pressure too high
Yeah it is lol!

How to build this intake thread coming soon.
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Last edited by Bmw doubles; 09-06-2019 at 07:42 PM..
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      09-06-2019, 07:53 AM   #2
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Lemme know how it goes. I am wanting a new intake too like that!
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      09-06-2019, 09:27 AM   #3
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keep up the great work idea and keep us posted. I thought about the same issue when it comes to the air coming into the turbo. It has to travel all over the hot engine bay before entering the turbo. But you have to understand that the car primary purpose wasn't for performance but more for luxury.
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      09-06-2019, 12:34 PM   #4
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I am very interested here. What are you doing for an air filter? Will that be a cone at the end of your intake?

Can you get any more pics of where the ram intake will end up?

Could it go in front of the radiator behind a mesh grille? that'd look sweet.

I love it.
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      09-06-2019, 01:42 PM   #5
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Following closely, awesome job. I would like to replicate
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      09-06-2019, 03:46 PM   #6
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Wait, is this also replacing the turbo inlet as well? That is very restrictive if so this is a 2 for 1.

Also what about some of the vents that go into some of the tubing you are replacing?
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      09-06-2019, 07:53 PM   #7
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Thanks, guys for all the support. As I'm chopping up stock pieces it's a little unsettling but they are spare parts so if I mess up the only harm is I spend a little more money getting new parts and loss of time. I'm happy to share the info I have now if anyone wants to follow along. I will disclose I've gotten a few things wrong so I was waiting to get all the parameters right and then share. If you want to try to catch up and follow along here's a shortlist.

- 2016 VW Passat intake
- Spare F10 intake
- Silicone coupler 2.75 to 2.5 connecting to the turbo intake
- 45-degree coupler 3.5 to 3 pointing into the air entry from the grill

The final parts I'm waiting for are
- black 3" 90 degree piping 12" in length
- elongated air cone
- heat shield for cone and additional material that extends the cone shielding and doubles as a scoop

BrowBMW the cone will be behind the grill. The custom heats shied scoop will be dope too! Also, in the pics you can see I will be attaching the custom inlet from AZ-MCRacer

Here are prelim photos of the upcoming air filter but not modified, yet.
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Last edited by Bmw doubles; 09-06-2019 at 07:59 PM..
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      09-06-2019, 08:19 PM   #8
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Why do you need heat shield if you are planning on putting the cone behind the grill?
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      09-06-2019, 08:34 PM   #9
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Quote:
Originally Posted by ziekxq View Post
Why do you need heat shield if you are planning on putting the cone behind the grill?
The heat shield is really a scoop in my case
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      09-06-2019, 08:43 PM   #10
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Here's a frontal look in the VW intake. It has that Squared shape on one side, but the 3.5 coupler is a tight fit and seals it up nicely.

Also here's a closer look at my gorilla glues/ plastic tack weld/ black silicone adhesive
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      09-06-2019, 09:33 PM   #11
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Awesome bro! This looks to be a great mod!
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      09-07-2019, 12:55 PM   #12
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Thick bead of flexible glue around the valve connectors. Looks ugly but I don't want the glue drying up and popping off under intense heat by the turbo. We'll see...

Next is the MAF sensor and cone by the grill and hopefully spool time dramatically increases.
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      09-07-2019, 01:09 PM   #13
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Following. I have been waiting 6 years for an intake behind the grill so we can really get to hear that growl. Hoping this works out!
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      09-07-2019, 01:46 PM   #14
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Quote:
Originally Posted by bake View Post
Following. I have been waiting 6 years for an intake behind the grill so we can really get to hear that growl. Hoping this works out!
$howtime456 has a custom solution too. Mine theoretically should. work without error. I'll share the final details tools needs, hardware, etc once it's complete.

Also if it works out maybe I'll have it 3D modeled and people can print their own.
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      09-07-2019, 02:38 PM   #15
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Quote:
Originally Posted by Bmw doubles View Post
Quote:
Originally Posted by bake View Post
Following. I have been waiting 6 years for an intake behind the grill so we can really get to hear that growl. Hoping this works out!
$howtime456 has a custom solution too. Mine theoretically should. work without error. I'll share the final details tools needs, hardware, etc once it's complete.

Also if it works out maybe I'll have it 3D modeled and people can print their own.
That would be awesome!!
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      09-07-2019, 03:38 PM   #16
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Quote:
Originally Posted by Bmw doubles View Post
$howtime456 has a custom solution too. Mine theoretically should. work without error. I'll share the final details tools needs, hardware, etc once it's complete.

Also if it works out maybe I'll have it 3D modeled and people can print their own.
You also need to get it CARB certified so those of us in the PRK can use it!
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      09-07-2019, 04:31 PM   #17
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Quote:
Originally Posted by ezaircon4jc View Post
Quote:
Originally Posted by Bmw doubles View Post
$howtime456 has a custom solution too. Mine theoretically should. work without error. I'll share the final details tools needs, hardware, etc once it's complete.

Also if it works out maybe I'll have it 3D modeled and people can print their own.
You also need to get it CARB certified so those of us in the PRK can use it!
Part of this experiment is to use a secondary set of hardware so come smog time just throw your stock gear back on with 0 modifications to get it back to original.
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      09-08-2019, 03:14 PM   #18
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G]https://scontent-lga3-1.xx.fbcdn.net/v/t1.0-9/54729963_10213497510847360_7169012436702330880_n.j pg?_nc_cat=108&_nc_oc=AQnW5iNoxeJV1tSmQqS1K179o_p3 tERPpk1_keZ3gGFprkoY3EJt2UkEWpumwABGmZg&_nc_ht=sco ntent-lga3-1.xx&oh=6fd78f85bc8e507ff05106be6b9fb7f7&oe=5DFB58 BB[/IMG]



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      09-08-2019, 03:18 PM   #19
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this was my prototype made. since then i went 4 inch skunk 2 velocity stack intake. Intake has a hole cut out on top of the cone to suck in the air. Good job BMW DOUBLES. Great effort and doing it for less than what i paid. This is a night and day difference especially upstairs. The sound is amazing at that.
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      09-08-2019, 04:58 PM   #20
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Quote:
Originally Posted by $howtime456 View Post
this was my prototype made. since then i went 4 inch skunk 2 velocity stack intake. Intake has a hole cut out on top of the cone to suck in the air. Good job BMW DOUBLES. Great effort and doing it for less than what i paid. This is a night and day difference especially upstairs. The sound is amazing at that.
Dope setup $howtime! I went 3" because that is the width of the air entry and I don't have to cut any metal.


I think you $howtime456 and AZ-MCRacer have the fastest F10 N55s on the boards right now. I'll catch up once I get my fuel situated.
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      09-08-2019, 06:45 PM   #21
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Creating the new harness extension is going to involve cutting the existing. Unless someone knows the female back to male connector for the MAF.

Here's what is needed:
- 16-18 gauge wire
- wire strippers
- Tesa wire loom tape
- electrical tape
- heat shrink tubing
- heat shrink butt connectors ( I'm not soldering )
- protective wire wrap
- heat gun
- test subject F10 MAF intake adaptor
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      09-08-2019, 06:52 PM   #22
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Quote:
Originally Posted by $howtime456 View Post
this was my prototype made...
My OCD (or is it CDO?) couldn't handle a visible intake on one side only. I would need one on each side.
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