Installed SURE Full 3 Aeros with 3" MAF (k04)

[dale_gribble]

Holy shit, that Aeros setup couldn't get bigger in any dimension and still fit with the battery there. It's like a gelatinous mass that contorts to fill the volume between the intake filter in front of the battery and the turbo. I had to trim my battery tray a bit and muscle the turbo intake hose into position. It took me a while to get a solid square grip on the turbo inlet with a hose clamp. I had to trim the battery hold down also and drill an anchor for the MAF housing.

By comparison, the 2.5" COBB TIH is much easier to install. This one takes a little more elbow grease. Previous to this install, I had a superb calibration on my MAF cal and was hitting my WOT AFR targets with the AEM + COBB, so I just upscaled my existing maf cal 19% (76.2mm^2)/(69.85^2) and went for a quick run.

I think my hunch was right; I think I found my car's weakest link in the AEM CAI + COBB TIH combo in relation to all of the other mods I have done. In a very short run, I saw my car flow ~250g/s at 5000rpms with more to give. Previously my car flowed 230g/s at 5000rpms. I am expecting to flow 270g/s @ 6,000, up from 250g/s with the AEM + TIH. WOT AFRs were ok from scaling up the MAF cal. The acceleration was near violent in the way the car responded. It really surprised me. My car usually pulls very smooth.

Of course I am going to quantify this with runs compared to my baseline. I will hopefully sneak in a few runs tonight to share. I am expecting some pretty decent gains with this intake on my k04.

[2.3speed06]

I've been thinking about getting this intake. But I think I'm flowing just fine with my C-PE set up at 280 :-)

[xb2ms3]

250g/s @ 5k doesn't seem like a big gain, I was getting about the same with 2.5" sri/tip. Ambient temp?

Can you post logs before and after 3" ?

[dale_gribble]

Ya, I will definitely post some logs. My k04 has always been flow challenged. It's a big deal for my car.

[ckMS3]

G/s isn't a great way of showing power my stock ko4 was flowing 330g/s during the winter but only making ~315whp. If your g/s increased that should tell you that you made some gains.

[dale_gribble]

Ya, I am not saying I have more power because of flow alone and I understand flow is relative. I am saying based on a solid baseline and a lot of empirical data that my car appears to be flowing about 20% more air through the maf compared to before. It is likely that this increase in airflow will contribute to more power.

[dale_gribble]

I am just prepping for my bnr which is next on the list.

[Lex]

First of all to make back to back comparisons in an MS6 you have to cal the MAF table so that your AFRs match with what they were previously.

Secondly, throw an AEM dryflow filter on there for maximum gains.

An increase in g/s (when properly calibrated MAF) when the WGDC is maxed out at the same temperatures shows an increase in flow.

[LilGator]

This guy was indeed a bitch to squeeze in there.

Considering this is a $400 SRI/TIP, why didn't Sure include a high flow filter?

This guy should work, yeah?

AEM 21-203DK 3" Inlet x 5" Element Dryflow Air Filter

AEM 21-203DK 3" Inlet x 5" Element Dryflow Air Filter
AEM 21-203DK 3" Inlet x 5" Element Dryflow Air Filter

[Lex]

The AEM filter should be this: 21-204DK for the 3" MAF housing.

[mczimer]

A better comparison would be from switch from a COBB SRI/TIP to this. I flow over 300g/s on my CPE SRI on the K04, so I am sure you have room to grow on your tune

[dale_gribble]

Originally Posted by mczimer A better comparison would be from switch from a COBB SRI/TIP to this. I flow over 300g/s on my CPE SRI on the K04, so I am sure you have room to grow on your tune

Honestly, Lex wrestled with my car on an e-tune for about 5 weeks... He noted early on that my car doesn't flow as well as others he has tuned in my area given similar conditions and fuel.

When he tells me my car is flowing as well as it can, my car is flowing as well as it can. My tune is about as dialed as it can get given my mods.

[JDW1]

I want one of these. How did you come up with the 19% increase for the cal?

[dale_gribble]

I came up with the 19% scaling factor from ms3blackmica's post:

MAF Calibration Tutorial

It was a great ballpark to start. My LTFTs are a little off and my WOT MAF cal needs a minor adjustment, but within 10% across the board.

[Keko]

Do you have any logs to show yet

[Karmat]

I'm really interested in the gains of a 3in MAF. I am currently sitting on a Cobb Intake without a TIP thinking this may be the bottleneck at this point.

What are your other mods?

[dale_gribble]

I have the CX racing fmic, internals, race pipe, 3" catback, AP, Stratified tune. I spent today getting my maf dialed in. I should have some good logs tomorrow.

Based on some prelims, this setup is flowing better than my aem cai + COBB tih. I just can't quantify how much better until I get wot maf Cal done.

[dale_gribble]

mmmkay. Here are prelims...

It was stupid hot here in SoCal again (93F in October, really?), so I had to run against an older baseline (same tune) where I ran at 93F. In the baseline run, I had an AEM CAI, all other mods were otherwise the same between the runs. In the AEROS run, I had the 3" AEROS system + MAF cal for Aeros system.

Here are two graphs; in one, you can see airflow g/s v. WGDC (%). In the other, you can see BATs/IATs v/airflow. The AEROS setup does flow more air than the AEM CAI across the board.





This translates in what appears to be a decent power gain for me. More importantly, it restored some of my car's performance even when running in higher temps. Log files are attached.

[dale_gribble]

Stand by for the 72F comparison where I stack my AEM CAI + Cobb TIH baseline against the 3" AEROS system. As soon as I can get a good comparison run, I will post results.

Based on what I know, I am expecting good gains over the AEM CAI/COBB TIH combo also. My car typically picks up about 10% more hp with a 20 degree outside temp drop. If I apply that to this graph, I should be seeing ~285HP which is a nice pickup from the AEM/COBB combo.

[dale_gribble]

One more thing regarding CAI v. SRI now that I have run both on the same car. I learned a few things. When cruising on the highway, my IATs are quite a bit higher with the SURE SRI than the AEM CAI setup. That's about where the advantages of the CAI end.

Once I start boosting or end up in stop and go traffic, the temps pretty much fall in line. I also learned that the IAT on the SRI is a pretty good representation of the engine compartment's ambient temp, which coincidentally is very close to the BATs. This taught me two things:

1. I was considering running one of those 'intercooler' pipes to replace one of the hot side pipes on my FMIC. However, after learning that the IATs and BATs kind of equalize in stop and go or when boosting, I don't see any value in doing so. The pipe can't dissipate any more heat of it is thermally equalized with the engine compartment ambient temperature.

2. Lower IATs don't have a proportional impact on BATs. It isn't a directly proportional, rather logarithmic. In other words, if you lower your IATs with a CAI by 10 degrees, it doesn't equal 10 degree cooler BATs, even when cruising. My BATs were pretty much the same between the two.

This is all probably common knowledge, but a reaffirmation for me. Also, I much prefer the sound of the SRI to the CAI. I won't miss the vacuum sucking sound of my CAI at all.

[mczimer]

I am really curious if there is any real gain from swapping a SRI setup to this. CAI's have long been shown to flow less, so that is obviously going to show some nice gains for you.

Since most people run SRI's though, I think that would be a good comparison for us looking to squeeze a few more g/s out of a setup

[fivefingerdeathpunch]

i am going big maf as well. hopefully once everything is dialed in i will be able to chime in here. i really want to see the difference between my CS TIP which is aluminum vs one of the silicone ones for BATs. the underhood temps in the speed6 are crazy so i'm convinced that doesnt help my bats at all. i have a fmic too so my bat arent that bad but it frustrates me seeing high bats.... yeah im BAT crazy...




see what i did there?


oh and for reference, my k04 maxes flow at 290g/s right now.

[Lex]

There's another ~7 g/s to be gained with the AEM filter in the top end. Well worth the ~$40.

[Lex]

And after that it's time to regain some of your intercooler's efficiency through WMI while increasing knock resistance at the same time.

[dale_gribble]

Originally Posted by Lex There's another ~7 g/s to be gained with the AEM filter in the top end. Well worth the ~$40.

Thanks! I just ordered one of these.

[dale_gribble]

So, it looks like after running the 3" AEROS 3" ID at 72F against my AEM CAI + COBB TIH, there is no real gains to be had with my current setup on the stock k04. It seemed to help at the higher temps as shown above which is great, but at the lower temperature, the runs were damn near the same. I might see a little more gain with the AEM dryflow filter with the SURE intake, we'll see.

The green line is the 3" AEROS and the yellow line is the AEM CAI + COBB TIH. Regarding the attached logs, '4th_72F_10512_2.16_NB_pass2_alone...csv' is the baseline with AEM + COBB TIH and the '2.20_72F_SB_passenger run 1.5.csv' is with the 3" AEROS.

Since I am going with a BNR at point, I imagine that the gains of the 3" AEROS will become more apparent.

[breakfstincluded]

Originally Posted by dale_gribble Since I am going with a BNR at point, I imagine that the gains of the 3" AEROS will become more apparent.

At first I was thinking that since the intake is silicone, you can't use an adapter when you have to switch turbos.

But BNRS3 is the same size, it hink ive heard a tiny bit bigger than the OEM 2" outlet maybe.

[dale_gribble]

I think I should be good to go for the BNR inlet with this intake.

[dale_gribble]

I decided to turn the Aeros Short RAM into a CAI; I ordered these two parts after taking measurements off of my AEM CAI tube. This should be plug and play, I will just need to find a way to secure the cold air tube to my car by the intake filter somewhere. The metal coupler will connect to the Sure Aeros MAF housing via coupler, and the air filter will screw onto the other end in the fender.

I figure I will paint the metal intake piece black to match the intake.

Metal coupler: 60 degree, 3.5" OD, 6" leg lengths, eBay PN 271074750025



3.5" intake coupler- 3.5" OD, ebay item 280896324664



As usual, I'll post logs when I convert this to a CAI.

[Lex]

Why not aluminum?

[dale_gribble]

Originally Posted by Lex Why not aluminum?

The tube is 6061-T6 aluminum.

[dale_gribble]

Here is how the CAI conversion turned out. I posted this in another thread-

http://www.mazdaspeedforum.org/forum/foru...ri-cai-133478/

I hacked about 2" off of each side of the aluminum 60 degree pipe to line the pipe up well with the AEROS MAF and into the fender. I made a custom mount for the CAI extension so the CAI can bolt to the body and take strain off of the SURE hose. I bolted this to the 3.5" tube with a hose clamp and aligned it for a good fit. I slapped the filter on the other size of the extension, and done. The whole thing took me about an hour. I am going to get the CAI extension powder coated black if I find there are gains from it.







I'll post logs when I get a chance. I am expecting to see cooler IATs and probably some gains from this mod.

[mrdouble99]

Can't wait to install mine

[cessnan1315efw]

If i switched my Cobb sf intake filter for one of those dry filter AEMs would I get any gain? Just wondering as my Cobb filter hasn't been changed in about 2.5 years. Thing looks clean tho!