Custom CAI and Head shield
#1
Custom CAI and Head shield
Hey guys, I figured I'd post my latest project so I could get some feedback from all of ya. So for the past month I've had the mod bug and have dropped more than enough money into my 545i. I was looking for some performance mods and after the ram air scoop I figured I'd get a CAI, but after reading the reviews of the AFE intake and the problems with heat soak i figured hey im an engineer time to build my own setup! So I went out to my local auto parts store, picked up a Spectre cone filter and some high temp engine paint. I then took a trip to home depot and bought a sheet of aluminum to make a heat shield and some weather stripping for the edges. I made a template out of some aluminum I had laying around and when I was satisfied with my design, I traced it onto my new piece of aluminum and put it together. In the end I ended up paying something like $55 dollars on everything and about 2 hours or so. After driving the car for a week I can definitely feel a difference. I have not dynoed the car so I can't say this is actually working but I know I havent lost any power. I have taken the car on multiple long hard drives and when I feel the filter its cool to the touch, but when I touch the heat shield it burns. Here are some pics!
#4
Members
Senior Members
Joined: Apr 2012
Posts: 953
Likes: 0
From: Concord, CA
My Ride: Alpine E60, '09 535i-Premium, Sport and Comfort Access PackageMods: Lux H8 V3 Angel Eyes, Weisslicht LED license plate lights, Interior LED lights, RPI Scoop, Matte Black Grills, Smoked LED side markers & side reflectors, 35% tint all around, and a 3
Looks good.
#5
I think I may do this, I've been on the self engineering mood lately, trying to think of all different crazy things to do. I'll give this a go, follow the way you did it and hope for the best.
Only question is how did u measure how high to cut the heatshield so it's flush with the hood closed?
Only question is how did u measure how high to cut the heatshield so it's flush with the hood closed?
#7
I actually made my template out of aluminum but I think cardboard would be much easier to use. Those clear hoses are from my oil catch cans. I have a thread somewhere about that project. I chose clear so I could see if oil was going through or not. As for measuring the height I just used the stock box and measured how tall that was and took like half an inch off so I could fit the weather stripping.
#8
New Members
Joined: Aug 2013
Posts: 75
Likes: 0
From: South Australia
My Ride: E60 01/04 545i - 19" Alloys
Nice work on the CAI AllBlackBMW! looks impressive! I just bought a replacement filter for my car before i browsed through the threads....
found my new weekend project coming up
any issues that you bumped into to note?
found my new weekend project coming up
any issues that you bumped into to note?
#9
Car feels like it can breath better and changed my exhaust note a bit with my straight pipes. ( for the good )
Something to note: wear gloves when cutting aluminum/sheet metal I forgot to, ended up cutting myself several times and bleeding all over the place. Also with that particular intake cone, its a little bit of a tight fit, but nothing problematic, just surprised me because it looked like there was going to be more room.
#10
New Members
Joined: Aug 2013
Posts: 75
Likes: 0
From: South Australia
My Ride: E60 01/04 545i - 19" Alloys
I did this last week, for $50 and some spare time its an awesome project.
Car feels like it can breath better and changed my exhaust note a bit with my straight pipes. ( for the good )
Something to note: wear gloves when cutting aluminum/sheet metal I forgot to, ended up cutting myself several times and bleeding all over the place. Also with that particular intake cone, its a little bit of a tight fit, but nothing problematic, just surprised me because it looked like there was going to be more room.
Car feels like it can breath better and changed my exhaust note a bit with my straight pipes. ( for the good )
Something to note: wear gloves when cutting aluminum/sheet metal I forgot to, ended up cutting myself several times and bleeding all over the place. Also with that particular intake cone, its a little bit of a tight fit, but nothing problematic, just surprised me because it looked like there was going to be more room.
The weather is going to warm up pretty soon over here... will be a good test cheers for the info