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PRL Motorsports 1.5T Cold Air Intake Development / Pre-Order

PRL Motorsports

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We are in the final stages of developing our 1.5T intake system before we begin production of our prototype piece. Once testing is done and the intake is finalized, production will take about 2 months to ship. Pre-orders and pricing will be available once testing is completed and production cost is finalized.

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It seems that many people modifying MAF cars have a misunderstanding of what exactly must be changed or be modified to make more power with an intake system. Bigger intake tubing typically yields more power through less restriction and more airflow, but increasing the size of the intake diameter alone isn't the only thing you have to worry about in a MAF based car. A MAF (mass air flow) sensor measures the amount of air flowing into your engine through an intake. Once airflow is measured the information is sent to the ECU to make sure the fuel injection system can control the correct amount of fuel your engine needs to perform properly at any given time in the rpm and load range given the amount of air.

Typically, the MAF sensor is located directly in the middle of the airstream within the intake pipe, usually located a very short distance after the air filter. MAF sensor wires receive an electrical current. Airflow cools the wires and changes the electrical resistance as air moves over it. The MAF calculates how much air is moving over the wires depending on how much the current changes. MAF sensor voltage is tied to a mathematical equation that the ECU calculates based on the specific diameter of the piping the MAF sensor housed in. A larger MAF housing means more airflow.

OEM manufacturers give cars a specific piping diameter from the factory that would allow a specific range of airflow to be read accurately by the MAF sensor. Once vehicles begin to make significantly more power, the electrical range of that sensor will become overwhelmed or maxed out due to the increased airflow, usually around 5 volts. When the MAF housing diameter is increased, more air is flowing past the MAF sensor at any given voltage.

If the intake tubing diameter has been altered, the MAF sensor will send incorrect information to the ECU. The ECU will see that a certain amount of air is being measured, but there is actually a larger volume of air at the same MAF sensor voltage. This is why most well-performing intake systems require a tune; larger MAF housings.

This is also why most of the intakes on the market are said to not require a tune. Are there minimal gains with these intakes? Debatably so, but let's not bash these companies. Their market is to offer a product that the average Joe/Jane can simply install and go with little-to-no tuning required, which is why so many "similar" intakes were so quick to come to the market.

However, not all hope is lost for people looking to go further. We have been working on developing cold air intake system that features a drastically larger (50% larger to be exact) MAF housing. Essentially this will be a full cold air intake, with the filter placement being down in the fender well. The intake starts at 4" and maintains a 4" volume throughout to the MAF sensor housing. The larger volume of airflow reduces pumping loss as well as creates an unrestricted air path to feed the MAF housing with ambient temperature air. The initial design has an approximately 50% larger MAF housing than stock, which will be desired for big power and/or turbo upgrades. The ultimate goal of here is to offer a proper intake system that draws in cold air and maintains a proper, steady MAF curve for ultimate driveability and performance.

This intake system is perfect for customers looking to see impressive gains with only a tune and will be perfect for big power and/or future turbo upgrades. It would be a shame to have to purchase another intake system in the future because you have exceeded the MAF housing.

This intake system will be constructed of muti-ply high-quality silicone hose, utilize our standard PRL Motorsports oiled air filters and stainless steel hardware. The thermal properties of the silicone are more desirable for this application, especially considering how the intake system is routed.



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NeoDragons

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cant wait :thumbsup:
 
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PRL Motorsports

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So we've been playing around with our new 3D printer and decided to print up a prototype intake system to check for fitment before we have a mold designed for a production piece. Fitment was spot on, stay tuned with us for better pics and info. Please keep in mind that this is just a rough prototype made out of printed plastic and isn't meant to be pretty. ;)

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The ID of the larger gray silicone piece is 4", including the odd "square" sections. Installation was a breeze, simply removing the bumper and moving the fender liner for a moment. The blue MAF housing will most likely be a machined aluminum piece designed to behave much like the stock MAF housing, but allow a much larger volume of air through it. This intake system will also utilize our standard oiled PRL cone filter.
 

HMan

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So we've been playing around with our new 3D printer and decided to print up a prototype intake system to check for fitment before we have a mold designed for a production piece. Fitment was spot on, stay tuned with us for better pics and info. Please keep in mind that this is just a rough prototype made out of printed plastic and isn't meant to be pretty. ;)

DSCN0248_zps7vs5hz2z.jpg

DSCN0245_zpsghkstyd1.jpg

DSCN0244_zpsxxkmblhh.jpg

DSCN0243_zps0ta3sjak.jpg

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DSCN0237_zpsr07nlna6.jpg

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DSCN0250_zps48brmjke.jpg

DSCN0236_zps7u3meazm.jpg

DSCN0235_zpskxqcjjfp.jpg

DSCN0233_zpsavjbetdg.jpg


The ID of the larger gray silicone piece is 4", including the odd "square" sections. Installation was a breeze, simply removing the bumper and moving the fender liner for a moment. The blue MAF housing will most likely be a machined aluminum piece designed to behave much like the stock MAF housing, but allow a much larger volume of air through it. This intake system will also utilize our standard oiled PRL cone filter.
Looks like it'll be a great piece @PRL Motorsports can't wait to see how it shapes up! Keep us posted !
 

SkyeHack

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I got you guys bookmarked. However, I will probably be buying for the Si. I am not sure fitment will be the same though. I guess we shall see next month.
 

touring420

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Will there be a short ram intake version? Don't think this will work with Canadian cars and the larger windshield fluid reservoir..
 
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PRL Motorsports

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I got you guys bookmarked. However, I will probably be buying for the Si. I am not sure fitment will be the same though. I guess we shall see next month.
Everything is looking like it will fit. Our Si will be in next week!

Will there be a short ram intake version? Don't think this will work with Canadian cars and the larger windshield fluid reservoir..
We will most likely be doing a short ram.


Our prototype silicone pieces arrived today just in time for us to finish machining the billet stock size MAF sensor housing. We will be installing and testing the stock size MAF tomorrow and larger race MAF next week when it is finished being designed/machined. We will work on refinining machining and whatnot for production, but we are more than pleased with what we've come up with. Here is what we have so far!

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NeoDragons

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Everything is looking like it will fit. Our Si will be in next week!



We will most likely be doing a short ram.


Our prototype silicone pieces arrived today just in time for us to finish machining the billet stock size MAF sensor housing. We will be installing and testing the stock size MAF tomorrow and larger race MAF next week when it is finished being designed/machined. We will work on refinining machining and whatnot for production, but we are more than pleased with what we've come up with. Here is what we have so far!

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eagerly waiting :D
 
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Well we finished our "Race" MAF today!

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We also got some sound clips for you!


All clips so far were with with the stock size "Street" MAF housing and off-the-shelf +6psi Hondata FlashPro Tune. Stay tuned for dyno results, fuel trim and MAF curve plot data and our "Race" MAF once we get this thing on the dyno with KTuner over the next few days!
 
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We decided to make two great revisions for you guys, one of which is due to a critical discovey we found while scanning the Si's factory intake system and air box. The non-Si 1.5T intake systems use a standard small-bore Denso MAF sensor like most of Honda's older platforms (8th Gen, 9th Gen, etc). However, the new Si uses a slightly larger MAF sensor with that varies in size/shape. For this reason we will be offering an Si-specific intake system and non-Si-specific intake system. Also, we have now implemented a bracket(s) to reduce flex in the intake system for optimal fitment!
 

JDM_DOHC_SiR

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Stay tuned for dyno results, fuel trim and MAF curve plot data and our "Race" MAF once we get this thing on the dyno with KTuner over the next few days!
Any updates to this from your testing?:hmm:
 

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We decided to make two great revisions for you guys, one of which is due to a critical discovey we found while scanning the Si's factory intake system and air box. The non-Si 1.5T intake systems use a standard small-bore Denso MAF sensor like most of Honda's older platforms (8th Gen, 9th Gen, etc). However, the new Si uses a slightly larger MAF sensor with that varies in size/shape. For this reason we will be offering an Si-specific intake system and non-Si-specific intake system. Also, we have now implemented a bracket(s) to reduce flex in the intake system for optimal fitment!

When will it be available for Pre-Order(Non-Si)
 
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When will it be available for Pre-Order(Non-Si)
We're expecting within 1-2 weeks. We made one last revision to allow better fitment. Once this revision piece is finished and approved we will put things into production and list a pre-order!

Any updates to this from your testing?:hmm:
Yes, we gathered some data with our Street stock-size MAF housing and put together a few graphs for you guys.

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Above is a graph of the long term fuel trims with the stock intake w/ air box and factory ECU mapping, or in other words a bone-stock car.

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Here is a graph of the long term fuel trims again with, but with our cold air intake (Street MAF) and factory ECU mapping.

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This is another long term fuel trim graph, but with our cold air intake (Street MAF) and +6psi Hondata off-the-shelf map.

Notice how consistent and similar all of the LTFT graphs are. Each graph is within -4 LTFT.

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Above is a graph of the short term fuel trims with stock intake w/ air box and factory ECU mapping (stock car).

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Here is a short term fuel trim graph with our cold air intake (Street MAF) and factory ECU mapping.

Civic%20x%20S.trim%20PRL%20intake%20and%20Hondata%206psi%20tune_zpscqlf4ni0.jpg

This is another graph of the short term fuel trims with our cold air intake (Street MAF) and +psi Hondata off-the-shelf map.

All of the STFT graphs display identical curves and consistency.

This data shows that our attempt to create an exact replica of Honda's factory MAF housing worked extremely well; we couldn't be any happier! We are confident proud to announce that our cold air intake system with the Street MAF housing is a direct bolt-on intake system with no tuning required! This is the first and CAI/SRI that we have EVER offered that doesn't require a tune. The beauty of this intake system is that customers can upgrade to our larger Race MAF housing to make more power in the future without having to buy a completely new intake system. We no longer have a shop EX-T for dyno testing, so we will continue dyno testing on our new shop Si as well as hand the Race MAF intake system over to @VitViper for his consensus whenever we are finished!
 

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