4200 & GS induction system development
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2b1ask1
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Well spotted Drew! I'm going to find time to go back through this thread and other conversations with people to assemble a list properly when I've go the prototype together on my car for the manufacturers to look at. The plan is to find a rolling road session I can set it up on with the prototype and then quickly swap it back to the old system inverted and held over the wing so there is a direct comparison available.
Basically they are happy to make all the mandrills and accessories to put a kit together based on a 'club' ordering 20 units as they have done for a number of other vehicles in the past. I don't see any difficulty getting 20 orders globally.
Basically they are happy to make all the mandrills and accessories to put a kit together based on a 'club' ordering 20 units as they have done for a number of other vehicles in the past. I don't see any difficulty getting 20 orders globally.
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Newton - I am in too.
Damon
Damon
2b1ask1
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Phil, getting my head fully around CAN-BUS systems in the van has to be No.1 priority for me at the moment then I can get on with this. I know exactly where I'm going with it, I just need a day to execute it. Then I need to find a rolling road for me and Mark so we can prove efficiencies with an near stock 4200 
and a modified GS and then over to the manufacturers. Realistically I would say orders late November and production for January/Feb 15. It is my intention to dispatch only as 100% complete kits including full instructions, two piece pipework, K&N, headlight and filter brackets, so it is minimal work for people to install. No price as yet but a loose ball park probably around £200 all in plus shipping.
The K&N is about £65 on its own, I expect we can improve that considerably with a big order.
and a modified GS and then over to the manufacturers. Realistically I would say orders late November and production for January/Feb 15. It is my intention to dispatch only as 100% complete kits including full instructions, two piece pipework, K&N, headlight and filter brackets, so it is minimal work for people to install. No price as yet but a loose ball park probably around £200 all in plus shipping.The K&N is about £65 on its own, I expect we can improve that considerably with a big order.
This sounds like a bloody good idea. After driving through standing water shortly after getting my 4200 GT, not knowing about the air intake placement at the time and the car stopped halfway through the flood :-(. The bill for towing it out, getting it home, then having the car checked out, new air filter etc was nearly £2k, and it hadn't luckily hydro locked!
2b1ask1
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Got a detailed look at the proposed route for the induction hose and it is not good news I'm afraid. There is no sensible modification to the twin plates beside the radiator. The problem is the bonnet catch assembly is actually on both plates! To maximise the internal area it will be necessary to build a metal tube more on this later.
2b1ask1
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Ok some numbers...
The true area of the throttle body and other fixed induction parts is around 6,000mm2 and the best linking pipework is ripple free silicone 92mm diameter or 42 radius (I.D.) or an I.D. of 6,647.61mm2 I can achieve this easily between the throttle body and the MAF. The difficulty is the sandwich gap between the side of the radiator and the headlamp made up of two formed metal plates, the inner mounts the bonnet catch torsion spring, the outer forms a headlight mount and (as it turns out) the bonnet release cable and actuator for the release spring. The former has a raised lug securing the tail of the spring and the latter is smooth but stepped in shape. If you peer down the right hand side of your grille you will see exactly what I am on about.
I had thought it would not be a problem to remove part or all of the outer piece and replace the headlight mount without an issue but it is more structural then I had thought and the added bonnet mechanism complicates things.
Back to figures...
Unmodified the gap between these plates can accommodate a rectangular box duct 4" tall by 2" wide giving an internal measurement of 100 x 50mm and an area of 5,000mm2 this however gives a shortfall of at least 1,000mm or realistically 1,660mm2 from the ideal. Left at this it ends up no better than the stock option which is restricted to something like 4,800mm2 in the worst parts.
So what to do...?
Well there is an option to modify the bonnet spring assembly and liberate the inner metal plate but I cannot see anyone wanting to do this and risk a bonnet popping at speed for the sake of an induction!
Having removed the air box assembly there is a secondary route for a duct through the wing under the headlight brackets but over the fog light and into the grill area in the same location. You could fit a duct of around 2,500mm2 in this position. splitting to two pipes and then combining before the MAF would achieve nearly 7,500mm2 but have the added drag of more surface area.
Thoughts please.
The true area of the throttle body and other fixed induction parts is around 6,000mm2 and the best linking pipework is ripple free silicone 92mm diameter or 42 radius (I.D.) or an I.D. of 6,647.61mm2 I can achieve this easily between the throttle body and the MAF. The difficulty is the sandwich gap between the side of the radiator and the headlamp made up of two formed metal plates, the inner mounts the bonnet catch torsion spring, the outer forms a headlight mount and (as it turns out) the bonnet release cable and actuator for the release spring. The former has a raised lug securing the tail of the spring and the latter is smooth but stepped in shape. If you peer down the right hand side of your grille you will see exactly what I am on about.
I had thought it would not be a problem to remove part or all of the outer piece and replace the headlight mount without an issue but it is more structural then I had thought and the added bonnet mechanism complicates things.
Back to figures...
Unmodified the gap between these plates can accommodate a rectangular box duct 4" tall by 2" wide giving an internal measurement of 100 x 50mm and an area of 5,000mm2 this however gives a shortfall of at least 1,000mm or realistically 1,660mm2 from the ideal. Left at this it ends up no better than the stock option which is restricted to something like 4,800mm2 in the worst parts.
So what to do...?
Well there is an option to modify the bonnet spring assembly and liberate the inner metal plate but I cannot see anyone wanting to do this and risk a bonnet popping at speed for the sake of an induction!
Having removed the air box assembly there is a secondary route for a duct through the wing under the headlight brackets but over the fog light and into the grill area in the same location. You could fit a duct of around 2,500mm2 in this position. splitting to two pipes and then combining before the MAF would achieve nearly 7,500mm2 but have the added drag of more surface area.
Thoughts please.