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Rhyscar's Toyota Levin - ‘fab it all from scratch’ project


Rhyscar

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  • 3 weeks later...

Been getting into modelling the airbox. Isn't as large as I initially thought so not too worried about 3D printing it now - its also got a good selection of curves and shapes to keep it strong. I've decided to add a sheetmetal alloy frame to the outside to provide a little extra support, but otherwise I'm confident in the strength it'll have. Next step is to slice off the first 2 trumpets and do a test-print to check for clearances

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The trumpets turned out pretty well. They aren't 100% perpendicular to ITB face, but pretty damn close. Making them perfect was an exponential amount more modelling work, so this will do. Trumpet approx 120-125mm long and goes from 49mm at base out to 63mm before the bellmouth. I'm going to be honest, it was pretty difficult to model a digressing profile swept through an arch...

Bellmouth has 20-25mm clearance in the tightest spots to the outer airbox walls. A little more would be nice, but struggling for physical space. I put some bulges in the base to help give a little extra clearance - hopefully while avoiding the alternator post & throttle cable which is pretty closeby. 

Perhaps I should reduce the taper on the trumpet and bellmouth size to create a bit more clearance?

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Airbox capacity just over 13L, so not as big as I'd like, but ramming air into it through the grill should make up for it. 

 

After a bit more deep diving I'm little worried about the 1.6L Peugeot 206  filter size - it's slightly smaller than a standard 2zz filter. K&N should be less pressure drop than factory, however, I'm also wanting as many doorts as possible. 

Unfortunately, I can't find anything off-the-shelf in a similar profile (95mm) but longer (>450mm). Another option is making my own filter from uni filter foam - would catch the bugs at least! 

 

Anyway off to the shed to solve the irritatingly-difficult-to-solve unlock reverse in my 6 speed gearbox. 

 

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When I was looking for a filter idea for echo (and future purposes) 

I did a sort by price on the repco website, and did a click and collect on 1x of everything that cost less than $2 on clearance sale. 

You're welcome to borrow the magic box if it's helpful hahaha

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You might be able to fit two of the Mercedes ones on top of each other if you want a long/skinny. 

https://www.repco.co.nz/parts-service/filtration/air-filters/k-n-performance-air-filter-33-2193/p/A1269832?rgfeed=true&cid=google-shopping&utm_source=google&utm_medium=cpc&gad_source=1&gclid=Cj0KCQjwsc24BhDPARIsAFXqAB1pM7TxCwegKJMgkEs4hOjCtq_VJ0QGd-1Uymoj8q0MXa8xR7-WTRMaAiFIEALw_wcB

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Thanks Dave and that is a brilliant idea for trying to figure out air filter sizes! I hadn’t come across that merc one yet.
 

Ideally I want one 600mm long and just under 100m high. 
 

My current method has been scouring through summit racing using the size filter to narrow my search 😆

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