Custom Airbox

[Fenham Dave 0]

Hello,

 

I'm after a bit of advice please - I need to sort out a better airbox solution for my 205 rallye (tu24engine). At the moment I'm using the original box that fits onto the back of the carbs, but the rest of the air inlet stuff is missing so I've got ITG sock type filters for each of the little trumpets in the box, and a wide diameter pipe from the front of the car to feed cold air in. The socks are getting a bit old now and I don't want to use these again because from what I've read they aren't very good.

 

I've also got an ITG megaflow filter like this one - http://www.merlinmotorsport.co.uk/p150/ITG-FILTER-JC40-100/product_info.html, but this is a bit too noisy without the airbox cover (great noise for a few minutes, but gets a little tiresome eventually and I can't hear my navigator !!). This filter seems to get the best out of the engine though.

 

So... as far as I can see there are three possible solutions

 

1. Try to source original tu24 airbox components - not really an option I think as they tend to rot away and there aren't available in the UK

 

2. Get a cone type filter to go on the end of the original airbox - would be OK I think but the engine runs quite hot already and this would be feeding of the hot underbonnet air - is this a problem ?

 

3. Get a custom airbox made up that would fit onto the baseplate for the ITG megaflow (could I put some noise eadening material on the outside of this ?)

 

I'd prefer to have a go at 3, but I would welcome any advice, especially if anyone has done anything like this before

 

Thanks,

Dave

[205Rallee 59]

Hello,

 

I'm after a bit of advice please - I need to sort out a better airbox solution for my 205 rallye (tu24engine). At the moment I'm using the original box that fits onto the back of the carbs, but the rest of the air inlet stuff is missing so I've got ITG sock type filters for each of the little trumpets in the box, and a wide diameter pipe from the front of the car to feed cold air in. The socks are getting a bit old now and I don't want to use these again because from what I've read they aren't very good.

 

I've also got an ITG megaflow filter like this one - http://www.merlinmotorsport.co.uk/p150/ITG-FILTER-JC40-100/product_info.html, but this is a bit too noisy without the airbox cover (great noise for a few minutes, but gets a little tiresome eventually and I can't hear my navigator !!). This filter seems to get the best out of the engine though.

 

So... as far as I can see there are three possible solutions

 

1. Try to source original tu24 airbox components - not really an option I think as they tend to rot away and there aren't available in the UK

 

2. Get a cone type filter to go on the end of the original airbox - would be OK I think but the engine runs quite hot already and this would be feeding of the hot underbonnet air - is this a problem ?

 

3. Get a custom airbox made up that would fit onto the baseplate for the ITG megaflow (could I put some noise eadening material on the outside of this ?)

 

I'd prefer to have a go at 3, but I would welcome any advice, especially if anyone has done anything like this before

 

Thanks,

Dave

 

Hi Dave,

 

Good to see another proper rallye up north!

 

I have tried every combination of the above on my TU24 Rallye over the last 20 years.

 

I tried the cone filter on the end of the airbox, but this didn't do much for the noise and it pulled in hot air. I had two underbonnet fires with the ITG filter. Then i ran a Pipercross filter (genuine works one from PTS in Coventry, very good but too noisey. Finally the best solution has been using the original airbox on the back of the carbs, with approximately 1 metre of 75mm diameter neoprene air ducting to the front of the car, then a cone air filter K&N (off an MGF race car) at the end of that. Then just cut out the back plate behind the grille to get the cold air. My car has got an Odyssey battery which is half the size of a std one and allows space for the ducting.

 

Combined with a fully heat wrapped exhaust you would not believe how much quieter the car is (although still need ear protection!) and how cool the underbonnet area is even when running flat out at events. Oh and it worked well on the dyno too.

 

Hope the attached photos help.

 

PS Pipercross do a cold airbox part number something like CX600, it was £250ish last time I looked, but not sure what the advantage was over the std airbox, a tenners worth of ducting and a £10 air filter! Dave

Edited April 18, 2011 by 205Rallee

[Fenham Dave 0]

Dave,

 

Fantastic answer thanks, and cheaper than the custom airbox too .

 

I think the exhaust wrap sounds like a good idea too - I've had a look into this and it comes in various sizes - do you know what size roll will do ?

 

 

Thanks again

Dave

[205Rallee 59]

Dave,

 

Fantastic answer thanks, and cheaper than the custom airbox too .

 

I think the exhaust wrap sounds like a good idea too - I've had a look into this and it comes in various sizes - do you know what size roll will do ?

 

 

Thanks again

Dave

 

Dave,

 

I got mine off e bay and I think it was about 50mm wide and 30 metres long. I thought that would be far too much and there was some left over, but it was so cheap (compared with Thieving Tweeks etc) I bought more than I thought I'd need. It was the first time I'd ever tried it and it was relatively easy, if time consuming to do. Despite dampening it there were lots of fibres flying about (ended up using my t shirt as a face mask...)

 

It's really effective, as you can touch the wrap when the engine is fully to temperature and it isn't very hot. People said the manifold would crack because the heat wasn't disipating, but mines done probably 10,000miles and 50 -60 events with no problems.

 

Regards

 

Dave