High Flow intake kit for Corsa B - Custom WORK — *PICS ADDED

[gsi8v]

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

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Last edited by gsi8v on 20 May 2019, 20:29, edited 1 time in total.

[Corsa Addict]

Looks neat. Well done

Price range? You planning on mass production?

[gsi8v]

Pics of the air box modifications.

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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.

Second cold air feed - 50mm diameter - fitted at the bottom left hand side of the airbox.

Before (top) and after (bottom)

[gsi8v]

Pics of work done on the throttle body

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Another two more coats

First two coats

Preparation is key

Ready to be sprayed

Shaped the flange to increase the radius of the opening

[gsi8v]

Throttle body - show case ready

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[gsi8v]

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.

[Corsa Addict]

[DJ7]

Would be interesting to see dyno results on the same day with the same car and using this and the standard stuff.

[gsi8v]

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.

[gsi8v]

And as with all great designs.... It's starts with a drawing!

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