Finally finished my XXL intake system for Evo 7/8/9 – designed to actually use the available space
Posted by AlexGSI@reddit | projectcar | View on Reddit | 57 comments
After way too many hours of CAD, test fitting and reworking details, I finally finished my XXL intake system for the Evo 7/8/9 platform.
The main idea was pretty simple:
Use the space in the engine bay properly instead of being limited by the typical small airbox designs.
So I built a system that:
\- runs a large diameter intake all the way from the airbox to the turbo
\- integrates a properly sized airbox instead of just a filter in the bay
\- keeps OEM-like fitment (no weird angles or forced routing)
\- still works with factory mounting points
Biggest challenge was honestly packaging everything cleanly without it looking like a random aftermarket solution.
It ended up fitting way more “factory” than expected – which was exactly the goal.
Curious what you guys think – especially compared to typical intake setups for these cars.
ONE1-ZERO@reddit
Serious props dude. What was the process? You 3d print it? I’m just getting into modeling and then production. Machinists background.
AlexGSI@reddit (OP)
Scanning, CAD, 3d Print :)
rulio57@reddit
Très bezu boulot .
TheOzarkWizard@reddit
Is that printed or molded and what material did you use?
AlexGSI@reddit (OP)
Its printed with Nylon CF
TheOzarkWizard@reddit
Thats super clean. Great job.
Successful-Ad-3993@reddit
Wow this is super clean, was this with nylon? Nylon fucken hates me so I couldn't imagine printing something this big, I do have some carbon fiber petg that has been extremely smooth to work with. You got me really inspired to CAD one up myself
AlexGSI@reddit (OP)
Its all Nylon CF, yes :)
Go for it 🕺🏻
Iconically_Lost@reddit
Nylon creeps my man. If its for the box, thts ok but any part that if post filter, that will worp and leak.
AlexGSI@reddit (OP)
Thats correct That why i annihilate (or however baking the parts is called) al the parts besides the Box itself
So ist should be good for about 170°C. If i have 170°C in ur turbo inlet .. i dont know If the Intake is Ur Problem 😃
But yes ... I could do PPS CF ... But that would be way more pricey
XZIVR@reddit
Damn, very impressive. I'm trying to print a custom intake elbow in ASA right now and the fkin thing just will NOT cooperate. One overhang curls up, catches the nozzle and game over. Which nylon did you go with? 6 or 12?
AlexGSI@reddit (OP)
Thank you :) Print slower or with thinner layers?
PA12 and PA612
AMetalWolfHowls@reddit
“anneal” and this is awesome! Super clean, and how the factory would do it if they did it today.
AlexGSI@reddit (OP)
A yes its spelled like that 😄 I throw all the small parts in my sunlu E2 after printing
So i hope that should be good. But we will see
AMetalWolfHowls@reddit
I just got my first printer and have no clue how to model anything, but I know some extra words :)
Successful-Ad-3993@reddit
Could I trouble you for the cad files of the airbox and intake scoop? I just wanna play around with it, im still extremely new to cad I'd like to see how you incorporated the cone filter into the airbox
AlexGSI@reddit (OP)
I dont give away my files. Once they are in the Internet, they are gone 😬 And to be honest ... The files are a mess of trial and error 😂😂
The airbox is relative easy ... Add some faces to a solid that fits the space. After that cut it into the Button part and the upper Part .. make both parts hollow ... After that, make cutouts where needed (MAF, Air Intake and Stuff)
Snorkel is a bit more work
StrikeouTX@reddit
Why wouldn’t you want others to have sweet intakes?
AlexGSI@reddit (OP)
I want to :)
And there are multiple ways to do this Buy them as a product Take the Idea and make it on ur own
StrikeouTX@reddit
I have and I do. I don’t even own a Lancer.
Think of all those files you’ve printed that others have R&D’d to make it a 1 button click print for you. If you need money out of it, then sell the files. People can just scan and print if you make this an injection molded product anyway.
Successful-Ad-3993@reddit
Honestly I cant hate you for that, I would've worked on it in onshape, and the moment you upload/create anything there its public domain so yeah understood, what's your opinion on spraying it after with a ceramic based paint like for calipers? Not so much for strength or anything but I had a theory that a ceramic paint would help deflect heat helping even more so with IAT granted on a more NA setup
AlexGSI@reddit (OP)
Thats a good question. I havent tried it and cant say anything about that. In theory it should work like u said. But i havent had any problems with heat soak as by now.
Successful-Ad-3993@reddit
Cant_Feel_My_Legs@reddit
This is the EXACT style thing I want to do with my stagea. Too bad I have no idea how to go about it lol
AlexGSI@reddit (OP)
I would say "Just start" ... But it Takes some time to understand CAD 😅
chungusamongusss@reddit
What a clean engine bay!
AlexGSI@reddit (OP)
I wish 😅
AmazonPuncher@reddit
And it makes no performance difference whatsoever.
AlexGSI@reddit (OP)
It can Support more airflow. So with it u can make more Power than with a Stock Airbox
corpsdawg@reddit
You should post this in /r/3dprintedcarparts.
Spoolra@reddit
Looks OEM on the first glance
mr_j_12@reddit
Such a cool airbox. Top work. 🤙
RiftHunter4@reddit
Thought this was OEM until the shot where it opened. Clean AF.
AlexGSI@reddit (OP)
Perfect 😂
Melodic-Ad1415@reddit
Did you 3d scan the open space or do it manually meaning math
AlexGSI@reddit (OP)
In scanned the engine bay :)
Melodic-Ad1415@reddit
Nice!
RIF_Internet_Goon@reddit
Wow looks OEM good job.
PumpedGuySerge@reddit
bro i truly believe its the effort on these seemingly negligible things is what makes the build unique in a "you" way, i know lot of people may not say that, but do feel better knowing theres a dude printing his 10th intake putting thousands of hours into his evo
im gonna finish every shitbox i have swear on this mans color matched battery
Hoovooloo42@reddit
Damn I didn't even notice the battery hahaha
AlexGSI@reddit (OP)
U got me with the color matched battery 😂😂😂😂😭😭😭
KermitHendrix@reddit
Saving for later inspiration as I also want to print a better intake
AlexGSI@reddit (OP)
Go for it 🕺🏻
Flostrapotamus@reddit
Are you going to sell this as a finished product or also the files? I have an Evo 8 and living in CA I have a modified stock air box to sit a cone filter inside it but this looks so much cleaner.
AlexGSI@reddit (OP)
I only sell it as a product
I already send two small OEM+ intakes to CA .. in january i think
driftking428@reddit
How hard is it getting parts for the Evo?
I'm considering making this my project car but I heard nightmares about getting Mitsubishi parts for a friend's 3000GT.
AlexGSI@reddit (OP)
3000gt is way worse ... Evo parts are okay to get .. expensive but u can nearly get anything
MechanicalGroovester@reddit
Badass!! Gotta love people who engineer their own solution to performance. 🔥 helluva design. Even more props for keeping everything close to the OEM routing and mounting! Great work!
jimbofranks@reddit
Now, that's an intake. Great job on using the factory mounts.
AlexGSI@reddit (OP)
Well to be honest, it uses the mounting points of the factoty mount 😄 But still No extra holes needed or something like that
Ok-You-6099@reddit
Nice work! The finish looks amazing, what printer did you use?
AlexGSI@reddit (OP)
Bambu H2S ... They just Print and Print and Print
flaming-bunnies-197@reddit
Looks OEM. To someone who doesn't know what printed surfaces look like, it may as well be OEM. Nice work!
AlexGSI@reddit (OP)
Yeah ... Killer move would be making a mold and make some Castings. But i dont want to know, how much this would cost🥲
Nylon CF has some nice finish so its like OEM-ish 😅
flaming-bunnies-197@reddit
Don't change a damn thing! it's awesome.
hellochase@reddit
this looks extremely clean and not being an expert on the Evo I wouldn't know it was aftermarket
what drove the choice of a cone (ish) filter over a panel element?
AlexGSI@reddit (OP)
With a cone Filter, the direction of the air coming into the airbox doesnt matter. If u have a panel filter in the airbox and the MAF is under this panel, u can only feed air from above the panel into the Box.
With this Airbox i use the OEM-ish snorkel in top and a big air inlet in the bottom of the Box... So i would need like 2 panels