Hidden Horsepower; Stock Intake + Silencer

B6 A4
#1

After going to the track last week and discussing a few things with Count we dicided to give a couple different things to try and help out the cars performance.

As you guys have seen in the CAI post, I had a CAI tube with a K&N cone that replaced my stock air box. That proved to be uneffective and actually lost power which caused a slower QM time. Count figured that would be the case but didnt want to spoil the results, thanks man…lol So in between runs I swapped out my tube and cone for the factory air box with 3 slight changes. There are 2 inlets on the box it self that needed to be covered to provide more suction. Don’t know the techinical names for them but here they are:
With the rubber gasket removed

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/91a80277.jpg

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/ea877175.jpg

Here is another piece that is in the front side of the box

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/97febe61.jpg

After those proved effective, I tightened up the seal and made the box as one.

With epoxy, some scrap plastic, my dremel, and a 1" pvc cap I made it even better. I cut out the scrap plastic into shape of the larger outlet hole that had the rubber gasget. I took some plastic epoxy and sealed the scrap to the air box, then took a quick couple coats of plastidip to seal it up and give it a cleaner finish.

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/9398c928.jpg

On to the smaller front circular piece. I took a 1" pvc cap and sanded the inside of the cap and outside of the box to fit the cap snuggly on the box.
Plastidiped that and looks good

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/6dd4559d.jpg

and the finally part of the air box, which I did first. Really isnt apart of the actual box but it is still helpful, where the car first starts taking in air you will see an opening, with 3 crossbars to help support load. Go a head and cut those out to free up just a little more flow,

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/5d30853c.jpg

Now on to the silencer, with your air box out and removed locate the piece that connect the MAF to the throttle body tube. You will see that there is a small box on the lower right of the tube that branches off away from the throttle body. This piece is the silencer. There is only one reason for this part, and that is to silence the air traveling to the TB. If you take off the TB inlet tube you can get to this piece a little easier to get too.

Circled in the picture is the silencer and its location

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/5524cf1c-1.jpg

There are 3 bolts that hold the silencer in place, 2 of which are on the block

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/60b01692-1.jpg

The 2 allen bolts that are in the lower portion of the pic. There is also another allen bolt that is further away closer to the throttle body. Once you have those out, if you havent already, unscrew the hose clamp that is connects to the TB tube. I found a pvc tube and cap laying around my house that fit perfectly snug inside the tube and capped it off and of course, plastidipped it
Such as this

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/9220ca07.jpg

Here is what the silencer looks like

http://i1102.photobucket.com/albums/g459/Nick_Mozingo/471d35ac.jpg

Now put your sealed air bix with all your parts a pieces back together to get that little oomph out of your 3.0
Go for a little ride after install, you will notice a little better throttle response as it gets a little crisper. With the car on and covers off, check and see if you can find any leaks, if not Damn good job to you.

Any questions let me know. Thanks to CountVohn for talking me through all of this and JHM

#2

Well guys we now have the first must do 3.0 free mod the Zingo airbox mod and scilencer removal. What a epically great post. I also have this mod done to my car per a preview of zingo’s test results and good conversation from the count. those results are below

The results a backed in science and technical data. Here is the Technical run down of the airbox and how the parts that zingo and I plugged off are actually part of the attempt to reduce air speed and to some extent volume.

http://audirevolution.net/addons/albums/images/862433931.jpg

So you can see from the technical data for the 3.0 that the back fender air scoop was actually designed to slow air speed thus the results we saw.

My take on the zingo mod are this. As zingo stated your actually making your airbox a pure sealed off unit. This way your not going to loose pressure. Before when you were doing 45mph or so the ram air part of your airbox was bringing in more air then the motor needed and pressure starts to build up in the air box. A good way to eliminate the pressure is to vent it off into the fender.

To vent the extra air into the fender helps keep the intake noise down but hurts performance. Keeping the air box as a high pressure zone helps speed the air going into the low pressure zine IE. your motor.

The testing I did was with the help of the count. We removed the scliencer from my car and the count brought over his airbox that had already been midifyed to eliminate the extra openings like zingo did. We made a piece of wood to go under the gas pedal so I could only pres the gas pedal so car. The idea behind the testing was to get on a long stretch of road and push the gas pedal the same amount and see how the MAF readings were effected and how the car accelerated at each point. These area ll things you can test with vag-com

Now remember this is the best home made testing we could come up with and I know some people like crazy data so this was the best test we came up with.

So with my stock airbox and the pedal fixed at… Im not sure exactly what % the block let me push the pedal I think it was about lets just say 20% the issue is that the pedal or throttle was openend the same amount with both airbox tests.

So the resutls.

With the stock airbox and the pedal locked at 20% the car was able to get up to about 57mph it took about 2 miles from a dead stop to reach that speed.

With the zingo airbox mod and the pedal locked at the same 20% you could really see the difference in the air boxmod. The car was able to get upto and past 58MPH MUCH faster. the car got to well over 65mph before we decvieded that was good enough and we had to stop due to trafic… IT was 1:40am you would have thought there would have been no traffic but there was. Either way it was clear the zingo bix mod helped.

So what does this mean. Why is the extra speed a big deal. Well what it means to me is that there is clearly more air being pushed into the airbox and thus by extension the motor with the same pedal position. This tells me that the motor is now more efficent due to the airbox mod. I did notice at higher speeds the car tends to be quicker to accelerate.

I don’t want to rammble on for too long but thats what I found. That along with zingo’s track results it seems like the CAI is bottom of the list when it comes to adding power and the free mod of the zingo airbox mod is the free gateway to a few extra ponies.

#3

Brillant thread and post, thanks for the info…

So now that we are feeding more air into the motor, is it time to look at a bigger throttle body?

Great work guys…cant wait and get out there a do the Zingo Mod ;D

#4

Wow not bad! This will be a nice little (& cheap) project over the weekend :smiley:

Keep up the good work and thanks for sharing!

#5

PS- Do you hear more induction sounds??

#6

Thanks there boys!

I just took her out for a little more “spirited” run again and I tell you it feels like another step, not like getting chipped again but it’s up there. The tune really takes control of the air coming in and forces it down your TBs throat. When you are rolling and you hit the pedal you hear it suck that air in and you feel the jolt. Instant response and brought a smile to my face each time I hit the throttle. We are getting somewhere guys.

Now our next goal needs to be getting the car off the line. Count! We need LA!! lol

You do notice a more suction sound but remember I was riding around with my cone filter on for about 8 months. Don’t know how to really explain it, but from the cone to the modded air box I feel that the sound is more pronounced. A lot stronger solid sound. Ahhhh I just can’t wait to get to the track…

You all have been warned… I’m going 15s…

#7

Interesting about the sound - the hot air intake that Zingo originally had is actually illegal here in Aus because of the increased intake sound and pollution laws. So increased intake sound with a OEM look and more power seems like a win win right there.

Work is so boring right now - That this mod has been the most exciting part of my day lol

#8

Funny thing is when I went out for a drive and took my camera, within the first 10 seconds of recording my camera died… Lol I like the sound though, it’s a win win for me

#9

If you dont mind, could you provide more details about the stock air box. I guess my real question is: what keeps it secure to the car? Is it a clip(s)? Screws?

If there are other tips dont hesitate to share! (like the kind of epoxy) Thanks in advance zingo.

#10

The actual air box it self is held to the car by 3 rubber type nipples I guess you would say. Two in the bottom that connects to the frame of the car and one that connects to the inner wall of the engine bay. Those alone hold it decent but it is the whole system that really sets it in place. From the scoop to the box, as the scoop connects to the top of the box which secures it a little more. From the filter side of the both it connects to the MAF to the tube that connects to the throttle body tube. That whole set up is what secures the system down. None of the parts or pieces we hack up or disconnect make the air box less secure. She is in there good-n-tight. So nothing you can break!!

Just be sure when you take out the silencer tube, you be careful not to hit any of the tubes or wires. Chances are the will be frail and ready to break on you.

The epoxy was just some extra (bumper repair?) that I had laying in the garage and it worked great.

#11

One more thing I’d like to add, do your self a favor and stop by autozone or somewhere that sells hose clamps like the ones used on my CAI. Replace the stock Audi ones that you have to clamp together to get off. I you are going to be messing with your air box and in that area you will thank me later

#12

Pretty cool, good job guys. Is anyone usign the K&N drop in filter??

#13

That’s the filter I have in right now

#14

have you had any problems with the MAF sensor? I was told that if I get one again and just clean it before I install it and never use the oil then I would be okay which makes sense BUT my concern now is how good the K&N can filter the air, if it doesn’t filter as good as a stock one then I don’t want to use it because I live in the desert so there is a LOT of sand out here.

#15

When I first had the cone on I had a few problems. I cleaned up the MAF with alcohol and just lightly oiled the filter. The drop in that I have in now I just bought the kit from autozone that comes with cleaner and oil. The best kind is the aerosol can spray. That way you don’t saturate the filter.
With the drop in I have never had a problem I say go for it just be careful with the oil

#16

I’d stick with oem in your case, the k+n doesn’t filter as much dirt as the oem one from what I’ve read, hence the increased airflow from it.

Stoked to do this mod on the weekend! I have extra plastic, caps and epoxy laying around too :stuck_out_tongue:

Edit: oops didn’t see Zingo already replied

#17

Thanks for the tips on the hose clamps and details about the air box mounting!

#18

AFE makes a dry filter, which is what I run.

Time to cut up that plastic undercarriage guard that’s been sitting in my garage forever.

#19

Oh thats right, the afe pro-s or pro-r? I think both are great dry filters.

Hahah see that box of plastic car crap we all have is finally getting put to use :stuck_out_tongue:

#20

I can see if I can get a video of the sounds if you guys would like. Dont know much you’ll be able to hear but figure I would ask.

I was actually going to check out and see how those AFI filters were possibly