A New Mishimoto BRZ/FR-S Intake, Part 1: Reasoning and Prototyping
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.
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.
As with other projects, development for this intake starts with stripping away the stock intake system.
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.
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.
Check back next time for a look at our process for creating the intake box design!