New Mishimoto Intake R&D!
 

Hey guys,

We've started a new R&D project for a second intake system designed for the twins. Check out the progress of development on our blog or posted within this thread.

http://engineering.mishimoto.com/cat...ntake-v2-2013/

A New Mishimoto BRZ/FR-S Intake, Part 1: Reasoning and Prototyping
Another Intake?

Wait … Mishimoto already has an intake for the BRZ/FR-S. Why design a second one? As this question crosses your mind, we can provide a simple explanation.

We have had great success with our existing cold-air intake system for this chassis, and the feedback from our customer base has been fantastic. Here is a look at our current product.

http://i62.tinypic.com/4qcs3.jpg
Mishimoto performance cold-air intake

After listening to our customers both directly and through web forums, we concluded that a second intake design was necessary for a completely different set of customers. Here are a few plans for our new design.

• Engine-bay mounted, stock-appearing airbox setup
• Easy installation and filter servicing
• Fits with Mishimoto direct-fit oil cooler kit
• Provide power gains over stock intake system

Our current intake system locates the filter behind the bumper. This requires bumper removal for both installation and filter servicing. Although this location would provide a rather cold air charge and would be less likely to experience filter heat-soak, we do realize that some folks are not interested in the slightly longer installation or servicing process.

Additionally, due to space constraints, several aftermarket intake options (engine-bay mounted) are not exactly compatible with our direct-fit oil cooler kit. We wanted to be sure that both of these products would function together without issue.

And finally, power gains. As with any intake upgrade, one expects a bit of extra power and torque, as well as an improvement in engine sound.
Prototype Development

As with other projects, development for this intake starts with stripping away the stock intake system.

http://i61.tinypic.com/apcnyp.jpg
Stock intake removed

http://i59.tinypic.com/qowxtw.jpg
Stock intake removed

We decided to start our system by creating the piping that would route from the throttle body to the air filter. Because we would be keeping the filter within the engine bay, we planned to utilize the stock air duct that feeds the stock airbox.

So we took the necessary measurements and modeled a design in 3D. We then decided to test our new 3D printer to produce a functioning prototype to test fitting and airbox development.

http://i59.tinypic.com/1zbv4li.jpg
3D-printed inlet tube installed

http://i62.tinypic.com/2rgge55.jpg
3D-printed inlet tube installed

Yes, our new printer does indeed print in Mishimoto orange. Pretty slick! You can also see that this setup places our filter directly in the path of airflow from the grille duct. Below is a straight-on shot of this pipe.

http://i60.tinypic.com/wqt3rt.jpg
3D-printed inlet tube installed

A few things to note about this piece. We are eliminating the noise generator and the intake resonator. A majority of 86 owners remove the sound generator, but we are confident that our customers will be pleases with our intake and with sound it produces, without the additional piping.

We are also utilizing our mass air filter (MAF) housing with an air straightener, both of which are included in our first intake kit. The air straightener helps promote laminar (smooth) airflow past the MAF sensor. This will provide the same drivability you will experience with the stock intake.

Last, we are also utilizing our oiled air filter. This unit provides greater flow and surface area compared to the stock paper filter, which should result in improved power output. This filter is fully serviceable and will not require replacement over time, unlike the stock filter.
Coming Up!

Check back next time for a look at our process for creating the intake box design!

http://i57.tinypic.com/2r3e8n4.jpg
Mishimoto prototype intake box

Thanks for reading!

-John

Grimmspeed Intake 2.0

Perrin V2 first pic and Grimspeed V2? is the orange thing?

We need more turbo's and header's too!!!

Mishimoto doesn't really do headers/turbos...but I'm sure if they did they would kick ass!

With that said, they put in TONS of time, effort and testing in to ensure their products work the way they should!

I was quite impressed when they came to my work and explained their processes.

Also, Mishimoto is an AMERICAN company...

Subscribed!

yea who is Grimmspeed anyway? they sound korean

I don't know. Matt and Chase are good with numbers though so it makes sense.

good with numbers how?

they're amazing business people and competent engineers..

race =/= competency or skillset

"Engine-bay mounted, stock-appearing airbox setup" .. I wonder if it's not worth to reuse something from stock airbox/snorkel, for even more "stock" looks, lesser price.
For example, set of smart mounting of this filter within that box + replacement airtube. Will complete stock airbox replacement to similar looking one really net much gains above that? But surely will rise price, shipping dimensions/weight/shipping costs ..

Glad to see there's another company looking into air straighteners on the intake. I have seen them used in the dirt bike world for years to help improve low end throttle response. I have been curious to see if a company will make something similar to FMF's Snap. http://www.fmfracing.com/Products/Accessories/632
Just a simple design that slots into the intake tube before the throttle body. I've heard they make a small noticeable difference but have not ridden a bike before and after to know for sure.

I love the clean look of it. The stock air tube is so weird with all the ribs and such. The tube is a silicone type material I assume? And I wonder what the top of the box would look like. I know you guys are set on the square box shape but I think a round box would be different compared to all the others available like the Injen, and would have less disruption of the air around the filter because of the sharp corners of the box.

Keep going! Looking good!

-RyanG

Air straighteners on our MAF sensor and General design is necessary to provide accurate readings for the maf, not necessarily to provide more erm.. Throttle response

It was a racist joke, lol.

Should really check out Grimmspeed's intake... they did thorough R&D and involved the community throughout it. The intake above is a complete copy of theirs unfortunately. Sorry, but I have to give credit where it's due. It just sucks that this is how business has come to where offshore they copy designs and mass produce to undercut to hurt the original people who created it.

Read through the Grimmspeed intake thread and you'll see why I chose it.

I read through it awhile back while debating which intake to run. I ended up with an injen and was pretty happy with it. Went back to stock a few weeks ago due to running an OTS e85 tune. If I end up back on 91/93 for long term grimmspeed will be on my car install until boost. Or maybe give ol mishimoto a try depending on their end result. I will agree I believe grimmspeed is the best intake out for our cars right now.

You must have misread what I was getting at, I am not talking about air straighteners on the MAF sensor. I understand the purpose behind that. I'm just glad there is another company looking into them in general considering grimmspeed is the only one for our cars right now. For placement I was referring to placing one right before the throttle body itself in the intake tube, smoothest possible air flow right before it enters the throttle body.. If it would actually make a small difference with these cars, maybe, maybe not. Doesn't hurt to try. If it supposedly has a small effect on dirt bikes, why not try that with our intakes. It very well could even be a placebo in the off road world too. :iono:

I'm still supporting @GrimmSpeed on this one. They are revolutionaries!

man traffic makes me cranky.. sounded a bit crass back there mate, I have the littlest of experience w/ dirtbikes so my statement doesn't hold water to those platforms, forgive the misinterpretation :respekt:

Its just paper filter, but if you need to "clean" engine bay go ahead or for pure aesthetic.

Thanks for all of the comments and interest guys!

I assure you that this product is not designed with an intention to copy or replicate any other offering on the market. As noted in our original post, we already offer an intake system with an externally located air filter. In order to provide an intake system for those who would prefer easier/quicker install and servicing, this intake setup will locate the filter within the engine bay in an enclosed box. As with any intake design, we will need appropriate airflow to the filter and using the factory ducting makes complete sense, which is why the filter/box location of nearly all aftermarket setups is similar.

Our intake setup will also be constructed in a similar manner to the systems we have been developing for the past few years. This includes a powder coated steel airbox or shroud, aluminum intake piping (or silicone pieces where applicable), an oiled and serviceable air filter, and the inclusion of an air straightener. An example would be our 08-14 WRX/STi system.

http://ep.yimg.com/ay/yhst-626316572...sh-2014-85.jpg

We put a great deal of effort into product design and we have no interest in copying or replicating any other products. In this case, we picked the best location for the airbox and we are following our normal product design and testing process. All product R&D is completed at our DE headquarters and we highlight nearly all projects within our engineering blog linked below (provides some insight into what is coming from Mishimoto).

http://engineering.mishimoto.com/

We will be posting up some additional R&D details soon with the full box design as well as initial testing results.

Thanks Shutter! We recently released a downpipe and cat-back exhaust system for the ’15 WRX. This is a new product line and has been quite an interesting endeavor. Although we do not currently offer a manifold/header, it could certainly be a product we explore at some point in the future. We are always interested in expanding our product line to better support enthusiasts needs.

Thanks!

Thank you Esco!

Thanks guys! The primary function of the air straightener is to provide laminar flow across the MAF sensor. This will ensure an accurate reading and provide stock-like driveability. If the stock intake system includes a specific feature such as this, we typically design such a component for our intake system.

Thanks for the kind words Ryan! The intake tube is going to be constructed from silicone in a similar fashion to the inlet tube we currently offer for the BRZ/FR-S. Our first prototype is more of a square design but a more rounded option is certainly something to consider. Thanks for the input!

Thanks guys!
-John

Round or squared should depend on if it's possible to make needed volume for stock like behaviour airbox within available free space constraints and free space shape. If no limits from those, then probably round box might be closer to selected round air filter shape / overall leave more room under bonnet (after all, IIRC round shapes contain most area/volume within set size. But then again often available free space is shaped in way that extra volume can be gained only by going squared).
I probably also would think a lot on best snorkel position and shape. If it's one time install, then customers might be willing to take off bumper for initial install. If it's for each filter change - that might cut customer count.

Thanks for chiming in Church! Very true regarding the filter servicing. Although it is relatively infrequent, some customers will have no interest in removing the bumper to clean the filter. We recognized this and decided to embark on the creation of our second intake option.

-John

LOL @ the Grimmspeed references.

Sure its a nice looking and probably high quality intake

BUT LMAO @ 10RWHP without a tune :lol: and a even bigger :lol: to those who believe it.

After seeing all the flames, deserved or not for the PLM header, I'm pretty disappointed to see people attacking Mishimoto for "copying" here.

There are not to many variations in making an ideal intake of this style, and if they do their R&D (and they will) and if Grimspeed does their R&D (and they did), you're going to find fairly similar and effective products from both companies.

Mishimoto or any other company could merely copy what has already been successful, but they're going about things the right way and it's sad to see people attacking them for it. It's not as though Grimspeed or any other company is claiming that an under the hood boxed cone intake is a new idea.

Thanks for the kind words Chad!

We should have an update on this project by the end of the week. :cheers:

Because copying two designs from two different companies in a row is R&D, right?

At least when Google takes someone's product, they make it better.

Anyone who thinks an CAI for this platform will create 10whp without a tune is smoking crack and any company claiming it is a liar.

So I give no kudos to Grimspeed and have no disdain for Mishimoto.

Its a freaking airbox for a tiny little engine. Hell the damn filter and box are in the same freaking place as stock. There is no new air intake and no new special sauce other than some nice looking housings and a cone filter.

How much air do you think a 2.0 liter 4 banger needs? If this engine was starved for air then maybe some of these aftermarket intakes would do some real meaningful hp gains. Thing is adding more air to an engine that already has plenty does not really do any good.

Liars

Looking good, i need to get some stuff from you guys since youre local!

Sorry you feel this way! As noted in our thread, each of our products undergoes rigorous testing and none of our results are skewed in any way. The plots from our cold-air system are an average of 3 consistent runs (for both stock and Mishimoto). We tested multiple MAF housing diameters which impacts AFRs. The combination of a scaled MAF and improved flow are definitely contributors to producing greater power output. This is shown in our development coverage below.

http://engineering.mishimoto.com/?cat=112

We did not make 10 whp from 3,000 rpm to redline but we did make power through a majority of the powerband and our 10whp/8 wtq maximum gains were achieved close to redline.

We are using the same diameter MAF housing with our new V2 system and it will be interesting to see if our results are similar with the new filter location.

Thanks

Thanks tdoggy!

-John

Project update! Check it out below.

A New Mishimoto BRZ/FR-S Intake, Part 2: Box Fabrication and 3D Prototype

We left off last time with an explanation of our intentions with this intake system and some initial design work to create an induction route to our planned airbox. Now it was time to finish designing this intake system so that testing could be conducted.

Airbox Fabrication

We started developing our airbox with simple metal fabrication. The plan was to put our idea into a physical object and then transfer this to a 3D model. Once in Solidworks, we could solidify the final design and features and use our 3D printer to construct a final prototype for test fitting.

Fabrication begins! A simple box was drawn up and templates printed for our bends and mounting point locations.

http://i58.tinypic.com/2hn5f77.jpg
Airbox frame template

Bends were made, holes were drilled, and here is what we ended up with.

http://i59.tinypic.com/2em1ov7.jpg
Airbox fabrication

http://i58.tinypic.com/2nkph54.jpg
Airbox fabrication

http://i62.tinypic.com/sqqh5w.jpg
Airbox fabrication

We then constructed a lid to contain airflow coming in through the scoop and to reduce the impact of engine bay heat-soak.

http://i61.tinypic.com/t4xs7l.jpg
Airbox lid fabrication

As noted in our first portion of this series, we wanted to ensure that out airbox would function with our oil sandwich plate and oil cooler kit. A few aftermarket intake systems are not compatible because they occupy the same space as the fittings we attach to the plate. Check out the clearance shot with our airbox!

http://i57.tinypic.com/ad0z0w.jpg
Oil cooler sandwich plate clearance

We then finished off the base of the airbox and ended up with our first completed prototype. Check out a few images of this!

http://i59.tinypic.com/2m64ls9.jpg
Mishimoto prototype airbox

http://i58.tinypic.com/24gp0r6.jpg
Mishimoto prototype airbox

As you can see, we are using rubber weather-stripping around all the edges. This provides a factory-like appearance and reduces any chances of noise created from vibrating components.

http://i61.tinypic.com/15exq2h.jpg
Mishimoto prototype airbox

Below is the lid for the box. This prototype unit is void of any mounting points. We will be adding holes to accommodate our mounting hardware.

http://i58.tinypic.com/16lkboy.jpg
Mishimoto prototype airbox lid

And our final assembled prototype!

http://i58.tinypic.com/2qs7b0g.jpg
Mishimoto prototype airbox, assembled unit

3D Prototype

After completing our fabricated prototype, we set our engineering team to work modeling this box in Solidworks. A few small tweaks and adjustments were made to the design as well. Once we had this complete, we decided to experiment a bit more with our new 3D printer. Printing this airbox was indeed within the constraints of the engine bay size, so we set up the printer and went home for the evening.

In the morning, we were pleasantly surprised with this!

http://i57.tinypic.com/ao45t2.jpg
3D-printed prototype airbox

http://i61.tinypic.com/25gszt3.jpg
3D-printed prototype airbox

Keep in mind some of the support material still needs to be removed from this printed box. Other than that, this turned out great!

http://i57.tinypic.com/m9aw3s.jpg
3D-printed prototype airbox

http://i62.tinypic.com/142hrwk.jpg
3D-printed prototype airbox

We then installed this prototype in our test vehicle to ensure proper fitment!

http://i60.tinypic.com/5n3giw.jpg
3D-printed prototype airbox, installed

http://i58.tinypic.com/eg2yhw.jpg
3D-printed prototype airbox, installed

http://i59.tinypic.com/2lswhg.jpg
3D-printed prototype airbox, installed

3D Models

Check out the final 3D models for this full intake setup!

http://i59.tinypic.com/2m3gsv9.jpg
Mishimoto intake 3D model

http://i60.tinypic.com/28rzdcn.jpg
Mishimoto intake 3D model

http://i60.tinypic.com/b8ty5g.jpg
Mishimoto intake 3D model

And one with the lid removed!

http://i60.tinypic.com/1kbdg.jpgMishimoto intake 3D model

Coming Next!

With a solid design in place, it was time to test this setup to see what kind of gains we could achieve in terms of power output.

Check back next time for a look at our testing process, results, and a video from our dyno pulls!

http://i60.tinypic.com/2cwr5l.jpg
Scion FR-S on dyno

Thanks for reading!
-John

Mishimoto: what do you think of fixing cover in place with something like sport hood pins for sake of style? :)

Interesting idea! I believe we are currently planning to utilize a black socket head bolt with a washer to prevent damage to the lid. I will certainly pass on the recommendation.

-John

Looks good, can't wait to see dyno results. Any idea of color options on the intake pipe? Or will they all be red? Rough estimate on price when it's said and done?

Is your intake tube compatible with your 1st cold intake system? I recently order your intake tube because I thought it has more potential compare to Perrins intake tube like installing the reservoir from the stock intake sound tube for example. Just for future reference when I come around to stop using the stock intake and go with a full cold intake system. Thanks

Just curious if any thought had been given to re-shaping the shape of the intake box as follows (see blue line below):

https://farm6.staticflickr.com/5324/...e5b9c359_o.jpg

Some of us with oil coolers have been looking for an intake box that:

1) Leaves plenty of space to run oil cooler lines/fittings near the oil filter
2) Allows the filter to be served through the engine bay
3) Draws cool air using the factory duct

I'm not an engineer, but reducing the volume of the airbox as shown above would probably prevent air from collecting in that empty space and be warmed up by ambient heat from the oil filter (and oil cooler lines).

Just some thoughts, not a critique of your design at all. :)

You'll have to wait for Grimmspeed's revision first so they can get a hold of it and copy it down to the perfect bend, weather stripping, and screw placement.

I have the Grimmspeed intake so I'm not likely to change (I did run your intake pipe prior to going to the Grimmspeed), but I wanted to offer a bit of advice based on my experience with their setup. Because of the flexible box material (aluminum) getting the lid in place and the screws on can be a challenge. If you could do studs on the box that the lid slips over and then nuts (heck you could use thumbscrews/wingnuts) to hold it in place, that would be much easier to install. Now, that said, I know that's going to be more expensive to assemble. But boy it would be more user friendly.