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Air Intake Project

2760 Views 35 Replies 13 Participants Last post by  chizzle1, 
L
I have checked around, and have been doing some research lately, on air filters and air intake systems. My goal is to slowly buy the correct parts and have the intake installed and running on my truck by the end of the year.

For simplicity, and over best results, I initially wanted to use an open element style kit, using a 10" or 14" round air filter.

In order to get enough CFM flow (for my wants), I would have to use a 14"x3" size filter element. There is no way I could fit a 3" tall filter on my truck. A 10"x2" K&N is only capable of doing about 690 CFM. The 10" filter also looks pretty small when mounting on a 360 V8 motor.

I tried fitting a K&K GenI FIPK, which I believe uses a 14"x2.5" filter. The fit was too tight for my liking, and I was concerned about the s-bolt (I am using a 1993 Dakota stock air filter housing bolt, which I modified and inverted), and general maintenance concerns with being able to easily access the filter, the TB, and the dist. cap/rotor.

So my research project began..........
Stock 5.9L 360/5.2L 318 Throttle Body: 635 CFM
Fastman 52MM TB: 825 CFM

I ditched the stock paper panel filter and I am currently using a drop-in K&N, until I can get all the proper parts for my own intake.

K&N Drop-In stock replacement panel filter: -#33-2084
-13.5” x 6.625” x 1”
-536 CFM

Even though I am sure the drop-in K&N flows better than the paper filter, as you can see, it still only is capable of handling 536 CFM. For $20 (what I bought mine for), it is a decent upgrade.

I then researched the K&N FIPK cold air intake kit for my truck. I really like the fact that K&N uses a large diameter flanged air filter, 4". However, if I would spend $300 on the FIPK, I was hoping it would flow more than a mere 659 CFM.

My goal is to make an intake that will be matched to the Fastman 52MM TB, and never starve for air flow.

K&N FIPK
-Kit #57-1511-2
-Filter #RC-4680 659 CFM
-Filter specs:(4” flange)6”base x 4”top x 7”long

AirAid CAI Kit
-13”x3.5” Tube
-Filter #700-420; 3.5” Flange
-6”base x 4-5/8”top x 9”long

I will have to say the K&N is very customer service friendly. Leon Collins has been great with providing myself with technical info and CFM ratings for all their filters. AirAid stated it is a rule that the CFM ratings are NOT to be released concerning all of the filters they use and sell. How pathetic! Anyways, I would imagine the #700-420 filter, that comes with the AirAid intake for my truck, ‘should’ be capable of flowing around 800 CFM.

Misc Filter:
K&N RE-0810 (3“ flange): 833 CFM
-Size: 6” base x 4.625” top x 9” long
-$46.95

Since I am going to use a 360 Air Intakez Big Mouth Air Hat, I am only concerned with air filters that utilize a 3.5" mounting flange. I have found a few other nice air hats, but they are $200.

K&N Round Tapered Filter Cones (3.5“ flange):
#RC-5112(rubber lid); 8”base x 6.625”top x 8”long
-CFM: 1102
-$50.99
#RE-0920(rubber lid); 6”base x 4.625”top x 9”long
-CFM: 800
-$43.95
#RE-0950(rubber lid); 6”base x 4.625”top x 6”long
-CFM: 600
-$39.95
#RC-3690(metal lid); 6”base x 4.5”top x 9”long
-CFM: 890
-$46.24
#RF-1004(metal lid); 5.5”base x 4.5”top x 8”long
-CFM: 1222
-$55.95
#RF-1045(metal lid); 5.5”base x 4”top x 8”long
-CFM: 715
-$43.95

K&N Round Straight Filter Cones (3.5“ flange):
#RX-4140(X-Stream lid); 4”base/top x 5.75”long
-CFM: 357
-$51.95
#RU-5114(rubber lid); 5”base/top x 5.625”long
-CFM: 612
-$38.69
#RU-1785(rubber lid); 5” base/top x 8.5”long
-CFM: 800
-$37.95

****prices are taken from Summit Racing’s website

If I do end up buying and using a K&n filter, it appears as if the straight cone style filters do not have enough surface filering area, and thus cannot flow enough CFM. So far it looks like the RC-5112 (a little too big in size) or the RF-1004 are the top filters of choice from the K&N filters.

360 Air Intakez and Intense Performance both use S&B Power Stack band air filters. As soon as I hear from 360 Air Intakez and Intense Performance, I will post the CFM results.

S&B filters are really nice because, unlike K&N filters, the top of the filters are not capped off by either a solid rubber or metal plate. The S&B filters have a design in which the top is also a filter, which increases the flow rating and surface filtering area. Plus, the air can flow through the top of the air filter, rather than only being able to flow around the circumference of the filter's body (aka K&N style).

K&N Engineering website:
http://www.knfilters.com/

Intense Performance website: http://www.intenseperformance.com/

360 Air Intakez website:
http://www.rncmotorsports.com/
http://www.360airintakez.com/store

Martel Brothers website: martelbrothers.com
-typically cheaper prices than Summit

Lastly, I have found a local tube/pipe supplier that stocks both aluminum and stainless steel pipe in the 3.5" diameter that I would use. This way, the air filter would use a 3.5" mounting flange, the pipe would have a 3.5" diameter, and the Big Mouth air hat also uses a 3.5" 'mouth'. This way, there are not any restrictions or reductions, nothing but smooth flowing air.

Any idea on which pipe would be better, the aluminum (T6061) or the stainless steel (304L)? Both have a .065 wall.
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M
Kyle, I don't know much about the k&n setups your talking about, but I wanted to give you another idea maybe you didn't research. I have a volant cool air intake on my truck. The reason I bought this one is because it truly is a cool air intake, it doesn't take air from the engine compartment like most others. Also available from that same company is a ram air tube that takes air from the front of the truck also. This is additional to the original cool air intake system. Here's the intake I have: http://www.volantperformance.com/pdetail.asp?ID=43

Just another option.
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M
For the price you pay for one of those full kits you coudl save a little more and get yourself roller rockers which help out more than the intake.

And I have heard that CAI do almost nothign and are a huge waste of money. I have heard this from many.
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P
I've heard that a drop-in K&N in the stock air box makes as much difference as a cold air kit.
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C
i put on a k&n gen II cai about 4 years ago on my 98 ram. i could tell a little difference. but not worth the $200+ i spent on it. probably better off buying a chip. the intake has started to crack on the bottom don't know why
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L
On 2005-11-29 20:36, chuckhines wrote:
I've heard that a drop-in K&N in the stock air box makes as much difference as a cold air kit.
Click to expand...

There is no way a 536 CFM drop-in filter will perform the same as 1000 CFM filter, I am going to use.

The problem with all of those expensive $200-$300 intake kits is the fact that the entire kit can only flow the the filter is capable of, and mostly likely is it still only 650-700 CFM. The air hat they use are very restrictive also.

Mikey, thanks but I am not going to spend $350+ on some rockers. My intake kit will cost around $100 and will flow better than most production made kits.
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L
On 2005-11-29 20:55, Cannonball wrote:
i put on a k&n gen II cai about 4 years ago on my 98 ram. i could tell a little difference. but not worth the $200+ i spent on it. probably better off buying a chip. the intake has started to crack on the bottom don't know why
Click to expand...

This is a huge problem with most K&N GENII FIPK kits. They use inferior plastic blends and the material around the air hat mounting area is very thin.

This is why I am going to use a 360 Air Intakez Big Mouth air hat. The plastic is very thick and made extremely well.
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C
A 10"x2" K&N is only capable of doing about 690 CFM. The 10" filter also looks pretty small when mounting on a 360 V8 motor.
Click to expand...

LPD111: I also am having the same problem, but I had a question that I was hoping you could answer since you have been researching K&N.
I have a 10x2 chrome hat intake, with a K&N filter. I know it flows a hell of a lot better than the factory box, but I also know there is room for improvement.
Rather than buy a completely new setup, I am looking into buyin the "x-treme lid" they have. It supposedly increases the CFM, but I don't know how much.
The cost for the lid for my application is about $50.
Do you think it would get me into the 750 range?
I also will be getting the fastman 50 or 52mm TB sometime soon.

pic of my intake: http://pg.photos.yahoo.com/ph/sgt_fuller_1979/detail?.dir=fce7&.dnm=ce80.jpg&.src=ph
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C
just out of curiosity is a round filter better than a fipk type setup even though theres hot air under the hood? i just want whats best for my truck. tom
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C
there was a LONG discussion about this a while ago, and it was determined that you still get more performance from the round hat intake than the stock box type, even though you get warmer air from underhood.
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R
why do you need so much air?the cfm rating on the fastman is probably at wide open throttle and unless you have bigger heads and headers with bigger pipes the engine is not going to be able to suck in that much air.
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C
:withstupid:
After looking at your sig line (LPD111) I am thinking the same as above. You need to, at a minimum, open up the bottom end also (decent headers, Magnaflow high flow cat system). To get the engine to breath more air in, it has to be able to push more air out.

I'm not saying you won't notice some gains if you do the air intake first, but it will be much more efficient if the above mentioned exhaust mods are done as well.
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T
Here you go. 3" tubing, bent, and expanded at the filter to 4". The filter is a K&N replacement for a stock GMC application. Dakota air hat, and a rubber connector off a Ford turbo intake tubing. Less than $100.

Oh and the K&N filter isn't canical, but a full cylider that's around 12" long with I'm guessing an 8" or so diameter.

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T
Another view.

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Identity Crisis
:withstupid:
...if one is good, two must be better!

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Identity Crisis
another angle...

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C
That looks nice, but any problems with water entry when going for a swim?
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Identity Crisis
never had it submerged. right before i sold it i had the two PVC pipes redone in stainless steel and moved a bit further forward. it came out really nice.
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M
I'm with Ram69, and chizzle1, why do you want such a high CFM rated filter?

I did a few quick calculations, and unless I'm mistaken (which could be, if so, please correct me) you don't need that much CFM.
what I came up with is this,
a 360ci engine turning 5K RPM, is only drawing in around 520 CFM
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L
On 2005-11-30 07:31, chizzle1 wrote:

I have a 10x2 chrome hat intake, with a K&N filter. I know it flows a hell of a lot better than the factory box, but I also know there is room for improvement.
Rather than buy a completely new setup, I am looking into buyin the "x-treme lid" they have. It supposedly increases the CFM, but I don't know how much.
The cost for the lid for my application is about $50.
Do you think it would get me into the 750 range?
I also will be getting the fastman 50 or 52mm TB sometime soon.
Click to expand...

Are you really sure that 10"x2" flows 'better'??? That sized K&N filter is only capable of flowing 400 CFM. Adding the Xtreme lid while only add 100 CFM.

A stock size K&N drip-in replacement panel filter flows 536, better than your 10"x2" with the flilter lid. Better rethink your intake ideas..........

The 14" round filters are a great simple air intake setup, if you can get a tall enough filter onto your truck. A 3" tall filter flows around 800 CFM. However, like I said, without a body lift there is not way a stock truck can safely fit that tall of filter. Add an xtreme lid and 60% of the filter lid is blocked and ineffective by the cowl and other engine parts.

Once again, if you have a body lift, without a doubt get a 14"x3"-4" tall fitler and forget about it.
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