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 Post Posted: 20 May 2019, 00:13 
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Joined: 27 Jun 2008, 21:27
Posts: 147
Hey guys,
I am looking to start building a portfolio of experience in building custom induction systems that is practical in theory– improves air intake velocity speed and density – and practical in design – easy to install/uninstall - with a top quality finish.
I did this set up for the OEM look but with the best possible performance. Here’s what I did to it.
Air box – Completely redesigned the bottom of the filter housing by closing off a section inside and adding a second cold air feed (50mm) for a smoother air flow through the air box. I removed the snorkel from the lid, filled away some of the grooves inside the lid for smoother airflow and on the outside for a unique look. The entire airbox was sanded down to a smooth finish, all rough edges and corners were smoothed.

Rubber air intake tube with IAT sensor – no changes by a good clean.

Throttle body – I stripped it down for a thorough clean. The flange was filled in a shape of a trumpet to open it from 57mm to 63mm. The rest of the bore was left standard size with 45mm butterfly. The inside including butterfly was polished – starting at 180grit and finishing at 320grit. The TPS was recalibrated using a voltmeter (0.6v at idle with butterfly closed and 4.6v at WOT)
All chrome parts were cleaned and polished, and the airbox and throttle was finished in high heat Matt black paint. I sold this with the K&N panel filter (had an old while laying around) to my buddy with a Corsa lite 1.4. It gave a noticeable difference in acceleration through the gears with a nice induction roar, purely because of the air flowing faster.

Hope you like my work! More pictures to follow


Attachments:
PSX_20190520_000835.jpg
PSX_20190520_000835.jpg [ 348.09 KiB | Viewed 1515 times ]
PSX_20190520_000847.jpg
PSX_20190520_000847.jpg [ 337.76 KiB | Viewed 1515 times ]

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2002 Opel Corsa Gsi ltd 1.6
Custom cold air induction system
Polished throttle body (53mm)
OEM exhaust manifold
50mm stainless steel straight through exhaust system
Smash & grab tint
Webasto tilt and slide (factory fitted)
Style inspired by Opel Motorsports


Last edited by gsi8v on 20 May 2019, 20:29, edited 1 time in total.
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 Post Posted: 20 May 2019, 07:49 
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Joined: 29 May 2007, 13:54
Posts: 49329
Location: Paarl...ex Durbs
Looks neat. Well done

Price range? You planning on mass production?

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 Post Posted: 20 May 2019, 19:42 
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Upgraded to a Flatbed Filter
Upgraded to a Flatbed Filter

Joined: 27 Jun 2008, 21:27
Posts: 147
Pics of the air box modifications.


Attachments:
File comment: Redesigned filter house. The left side of the airbox was closed. I did this for two main reason:
1. To eliminate disruption of air flow in the air box.
2. To suck more air through the cold air feeds by reducing the space inside the air box.

PSX_20190520_162522.jpg
PSX_20190520_162522.jpg [ 228.67 KiB | Viewed 1498 times ]
File comment: Second cold air feed - 50mm diameter - fitted at the bottom left hand side of the airbox.
PSX_20190520_162512.jpg
PSX_20190520_162512.jpg [ 244.33 KiB | Viewed 1498 times ]
File comment: Before (top) and after (bottom)
PSX_20190520_192421.jpg
PSX_20190520_192421.jpg [ 381.95 KiB | Viewed 1498 times ]

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2002 Opel Corsa Gsi ltd 1.6
Custom cold air induction system
Polished throttle body (53mm)
OEM exhaust manifold
50mm stainless steel straight through exhaust system
Smash & grab tint
Webasto tilt and slide (factory fitted)
Style inspired by Opel Motorsports
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 Post Posted: 20 May 2019, 19:50 
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Upgraded to a Flatbed Filter
Upgraded to a Flatbed Filter

Joined: 27 Jun 2008, 21:27
Posts: 147
Pics of work done on the throttle body


Attachments:
File comment: Another two more coats
PSX_20190520_191016.jpg
PSX_20190520_191016.jpg [ 321.36 KiB | Viewed 1498 times ]
File comment: First two coats
PSX_20190520_191004.jpg
PSX_20190520_191004.jpg [ 246.62 KiB | Viewed 1498 times ]
File comment: Preparation is key
PSX_20190520_190939.jpg
PSX_20190520_190939.jpg [ 295.93 KiB | Viewed 1498 times ]
File comment: Ready to be sprayed
PSX_20190520_190917.jpg
PSX_20190520_190917.jpg [ 369.66 KiB | Viewed 1498 times ]
File comment: Shaped the flange to increase the radius of the opening
PSX_20190520_162752.jpg
PSX_20190520_162752.jpg [ 266.33 KiB | Viewed 1498 times ]

_________________
2002 Opel Corsa Gsi ltd 1.6
Custom cold air induction system
Polished throttle body (53mm)
OEM exhaust manifold
50mm stainless steel straight through exhaust system
Smash & grab tint
Webasto tilt and slide (factory fitted)
Style inspired by Opel Motorsports
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 Post Posted: 20 May 2019, 19:59 
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Upgraded to a Flatbed Filter
Upgraded to a Flatbed Filter

Joined: 27 Jun 2008, 21:27
Posts: 147
Throttle body - show case ready


Attachments:
PSX_20190520_191115.jpg
PSX_20190520_191115.jpg [ 473.99 KiB | Viewed 1498 times ]
PSX_20190520_195449.jpg
PSX_20190520_195449.jpg [ 374.92 KiB | Viewed 1498 times ]
PSX_20190520_190810.jpg
PSX_20190520_190810.jpg [ 372.12 KiB | Viewed 1498 times ]
PSX_20190520_190759.jpg
PSX_20190520_190759.jpg [ 422.18 KiB | Viewed 1498 times ]
PSX_20190520_190848.jpg
PSX_20190520_190848.jpg [ 381.19 KiB | Viewed 1498 times ]

_________________
2002 Opel Corsa Gsi ltd 1.6
Custom cold air induction system
Polished throttle body (53mm)
OEM exhaust manifold
50mm stainless steel straight through exhaust system
Smash & grab tint
Webasto tilt and slide (factory fitted)
Style inspired by Opel Motorsports
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 Post Posted: 20 May 2019, 20:13 
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Upgraded to a Flatbed Filter
Upgraded to a Flatbed Filter

Joined: 27 Jun 2008, 21:27
Posts: 147
Corsa Addict wrote:
Looks neat. Well done

Price range? You planning on mass production?


I sold this set up for R750. The airbox and filter was laying around in my garage and I wanted to make the most of my money back from the filter.

I'm not looking to mass produce this one, I but I do have a cold air intake system design for Corsa B 1.6 that I could look at mass producing. I'll post some pics the moment I have a final design.

This is post is show my workmanship and design theory I apply when it comes to improving air velocity speed and density for anyone who is looking for someone to build or improve an intake system.

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2002 Opel Corsa Gsi ltd 1.6
Custom cold air induction system
Polished throttle body (53mm)
OEM exhaust manifold
50mm stainless steel straight through exhaust system
Smash & grab tint
Webasto tilt and slide (factory fitted)
Style inspired by Opel Motorsports


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 Post Posted: 21 May 2019, 09:38 
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Joined: 29 May 2007, 13:54
Posts: 49329
Location: Paarl...ex Durbs
:thumbup:

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 Post Posted: 24 May 2019, 10:06 
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Turbocharged
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Joined: 07 Aug 2008, 13:00
Posts: 7774
Location: just cruising...
Would be interesting to see dyno results on the same day with the same car and using this and the standard stuff.

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Current: '05 VW Golf 5 2.0 TDI Sportline
Ex: '97 Opel Astra Estate 200i
'00 Opel Corsa GSI 2.0 16v
'96 Opel Astra 200i E 16v
'02 Opel Corsa GSI 1.6
'93 Honda Ballade 160e 16v
'95 Opel Astra 200i E 16v


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 Post Posted: 25 May 2019, 11:40 
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Upgraded to a Flatbed Filter
Upgraded to a Flatbed Filter

Joined: 27 Jun 2008, 21:27
Posts: 147
There wouldn't be much of a difference in the kw curve because the throttle still only let's in so much air. There should be a difference in the torque curve as air will flow faster in to the cylinders, increasing acceleration.

But it would be interesting to see what difference this set up would make on a dyno.

_________________
2002 Opel Corsa Gsi ltd 1.6
Custom cold air induction system
Polished throttle body (53mm)
OEM exhaust manifold
50mm stainless steel straight through exhaust system
Smash & grab tint
Webasto tilt and slide (factory fitted)
Style inspired by Opel Motorsports


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 Post Posted: 25 May 2019, 11:57 
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Upgraded to a Flatbed Filter
Upgraded to a Flatbed Filter

Joined: 27 Jun 2008, 21:27
Posts: 147
And as with all great designs.... It's starts with a drawing!


Attachments:
PSX_20190525_115318.jpg
PSX_20190525_115318.jpg [ 259.61 KiB | Viewed 1438 times ]

_________________
2002 Opel Corsa Gsi ltd 1.6
Custom cold air induction system
Polished throttle body (53mm)
OEM exhaust manifold
50mm stainless steel straight through exhaust system
Smash & grab tint
Webasto tilt and slide (factory fitted)
Style inspired by Opel Motorsports
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