Custom made 2.2D intake (Diesel)

[Uncle George]

Ever since purchasing the 2.2D, I've really missed the induction noise from my previous turbo cars, such as the late Opel Astra and Captiva 5 turbo diesel. Hell even my supercharged Mini Cooper S sounds pretty amazin!

JUST want to hear that turbo sucking air!!!!!

There are a couple of kits available at the moment, unfortunately all of the ones I could find utilize the factory airbox. I've tried several mods with the airbox but none introduces the classic turbo induction noise.

HKS's pipe is beautiful!, AUTOexe offers a simple solution, but I want noise and I think my best chance comes from a pod filter.

So I've begin to search for weld-smiths around my town and to my delight I've found a reputable shop about 50 minutes drive away, situated in the middle of rice fields! Lol, classic Asia situation I thought.

After explaining to the owner what I wanted to build, he simply said, "that's easy", he will go and source a few parts and asked me to come back when I can leave the car with him for a good couple of hours.

The next time I saw him is a week later, sure enough he has sourced two air filters, various silicon connects and various stainless steel mandrels and straight sections.

A few photos I've taken

The engine bay

So much space after the airbox is removed

Rolling detents for the silicon pipes

While I was there for the day, I got this installed too. Carbon fiber exhaust tips. ..

 

[Uncle George]

After the pipe has been made, I went out for a spin. It sounds great! But the engine wasn't happy. The idle was rough and soon check engine light came on.

The car limped back to the shop and a few adjustments was made to the vent tube position - after which it now idles smoothly and "normal". However when boost came on it the engine started to surge again - at this point of time we are running out of day light so I've decided to call it a day and returned the car back to OEM configuration.

After a long night thinking what could be the issues, I gave the shop owner a quick call and said I've had an idea and asked to make a few modifications and corrections - after a few hours of tweaking now the turbos sings loud and it makes good power - my ear and butt tells me.

But the pipe is now in a pretty ugly state, it has been cut and shunt a few times, has been epoxied and has all sort of different diameters of sections on it.
Not to put his effort into waste, I suggested it would be great if he could use it as a template and make a limited run or CX-5 2.2D induction pipes and offer them to the general public. =)

So, that's where it is at - at the moment.

During this time, Sassimac has messaged me about the Check Engine Light I was getting with the old pipe, I've passed him the good news that it is now working and the induction noise sounds great! He has kindly suggested I should do a few runs and log a few parameters - such as air flow, temperature, boost and etc. (why didn't I think of this).

Well, when the new pipe is ready, I'll do a back to back measurement!

== Background ================

My CX-5 is currently running Sassimac's engine tune,
http://www.mazdas247.com/forum/showthread.php?123839126-ECU-tuning-the-2-2L-Diesel

I know normally a pod filter won't add power, if anything it actually decrease power due to hot engine air. I'm doing mod for induction noise and not for absolute power. I'll later build an half box to shield it from hot radiated air.
Right now, I get torque steer and the traction control light tells me it's struggling for traction in first and second gear when doing 0-100km/h run =)

 

[metalfab]

I don't see it in the photos: get a face shield or at the very least wear eye protection. I've seen what happens to someone when a 10,000rpm cut-off wheel shatters. Also, TIG welding without a helmet?! Over here you'd get fired for both of those issues.

 

[Chris_Top_Her]

Imo, if you are adding parts that potentially affect the motor/performance, you should have some way of even basic data collection/monitoring.. torque for example free or pro ~$3.00 (android) + a $10 Bluetooth OBD2 adapter. There are other programs too. These will allow you to see the change in 0-60 boost level, *estimated* (regardless of the actual hp number it's pretty consistent on a given set up) hp intake temp, airflow CFM etc.. all those for less than $15, as long as you have some android device. That maf is literally right in front of the intake.. on the oem intake it's much further down the intake line.. You would probably need to start by lengthen that pipe and moving the maf back/changing it's diameter until the cel is gone

 

[metalfab]

Turbo or not, without a larger throttle body, headers, etc to help pass all that air in and out efficiently I doubt you'll see any performance increase.

 

[SayNoToPistons]

Throttle body would be the last concern for power increase...

 

[Uncle George]

LOL,

Trust me, I'm very very not used to how things work in Asia too. Standards are simply different.

If it's me, I would have put on every single piece of safety gear. I have asked him about his welding, apparently he has been doing welding for 20 years. Somehow he actually uses his thumb to block the light from the arc and shields his eyes. =_= Notice the shadow casted.

I don't see it in the photos: get a face shield or at the very least wear eye protection. I've seen what happens to someone when a 10,000rpm cut-off wheel shatters. Also, TIG welding without a helmet?! Over here you'd get fired for both of those issues.

I'm not doing it to add power~ I just want to hear the turbos.

Throttle body would be the last concern for power increase...

 

[Sassimac]

Hi All...

I must say that I'm hugely impressed by the effort here..!!

The thought and time you have put into this is obvious via our Skype chat. All my thoughts regarding ID's and flow etc, have been addressed. Good on you..!!

As discussed, data logging (forget these apps and your phone) can be better done by MazdaEdit for now. It has a full well featured data logger built right in. Consider PID's like:

- RPM,
- Vehicle Speed,
- IAT,
- MAF g/s,
- MAT volts,
- MAP,
- Accel position,
- Desired IQ.

That will give us a really good idea of before and after..!!

Again, I feel you've done a "bang up job."

Cheers.

 

[RedPanda]

Awesome, can't wait to see the final product!

 

[SayNoToPistons]

LOL,

Trust me, I'm very very not used to how things work in Asia too. Standards are simply different.

If it's me, I would have put on every single piece of safety gear. I have asked him about his welding, apparently he has been doing welding for 20 years. Somehow he actually uses his thumb to block the light from the arc and shields his eyes. =_= Notice the shadow casted.

I'm not doing it to add power~ I just want to hear the turbos.

The welds are good with consistent bead, minus a small sloppy spot where the MAF housing meets the pipe. Oh well, you are paying for the final product, not his safety LOL.

Please post the data logs if possible. No SkyA-D here in North America and posting the logs would satisfy a bit of curiosity.

 

[metalfab]

The welds are good with consistent bead, minus a small sloppy spot where the MAF housing meets the pipe. Oh well, you are paying for the final product, not his safety LOL.

The welds are nice but I'm not so sure why the lack of safety is funny to you.

 

[SayNoToPistons]

Like that welder really gives a damn what others think?

"You can lead a horse to water, but you can't make him drink."

 

[Chris_Top_Her]

The welds are nice but I'm not so sure why the lack of safety is funny to you.

 

[metalfab]

Exactly peoples problems these days: they don't care and have no accountability.

 

[Chris_Top_Her]

Exactly peoples problems these days: they don't care and have no accountability.

Or, because he lives in a different county, with different cultural expectations, laws and safety regulations, I don't feel it necessary to push my standards etc onto him. Especially since the op voiced his concern. In my 25 short years I've had the privilege of living and traveling overseas, and people simply do things differently. People will make unsafe decisions regardless of how many government laws are stuffed down your throat, whether there is a statistic in favor of it or not and definitely not just because someone who (supposedly) knows better said so.

 

[metalfab]

Believe it or not, my opinion is one of caring. The welder in the photo has talent, I'd hate for him to injure himself because of lack of safety. Maybe he doesnt make enough to afford gear, salaries differ in other counties. If I had $300 to spare I'd send him a welding helmet.

 

[SayNoToPistons]

Look at his fab machinery and tools... I'm sure he makes more than enough for a welding helmet. Hell, you can get an auto-dimming one for $40 USD made by Northern these days. He resides in Taiwan. Not exactly a third world country. The welder clearly prefers not to use a helmet. Certainly doesn't look like a fabrication newb either.

 

[metalfab]

Look at his fab machinery and tools... I'm sure he makes more than enough for a welding helmet. Hell, you can get an auto-dimming one for $40 USD made by Northern these days. He resides in Taiwan. Not exactly a third world country. The welder clearly prefers not to use a helmet. Certainly doesn't look like a fabrication newb either.

Might not be his shop, who knows. Also, I never said he looked like someone new to the trade.

As for a $40 auto dimming welding helmet compared to a $200+ Miller Performance model, there is no comparison. Speed of the lens dimming (important), adjustable lens shades to set to different amps and processes, sensitivity adjustments, comfort and weight, outer and inner clear lens availability, overall build quality. Its a welders main tool and should not be cheaped out on. I'd rather have a solid shade than a cheap auto-shade helmet.