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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Mon, Jan-15-2018, 07:30:32 PM   #1
HassanEido
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Default My Custom CF Airbox Journey Begins

Welp. It's that time of the year again.. Another custom project has begun. A couple of people here know I've been toying with the idea of creating my own csl airbox.. inspired by an old thread of a guy who actually did his own box a couple of years ago, I figure what the hay-Why not
So I bought 8 square meters of 200 grams per meter twill weave carbon fiber fabric, epoxy resin, bought a spare stock airbox to reuse the trumpets and backing,took a couple of online courses on composites, and ordered a csl filter, which should be arriving this weekend.
I plan to make a foam form and wet lay cf on top of it to make my box,clocking the weave layer by layer to achieve max composite strength,for my first iteration anyway.
I'll be updating this thread when I start working on it, and when the time comes with dyno graphs as usual.

Here's a teaser for now :
IMG-20180110-WA0051.jpg
Screenshot_20180115-221904.png

Edit: Results and Dyno and vids:
http://m3forum.net/m3forum/showpost....&postcount=123
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Mods:
-Custom CF airbox
-SSV2 catless headers, Custom 2.5" dual sec1, Custom sec2 2.5" dual with e9xM X pipe, SuperSprint Race inspired custom section 3..
-Cat Cams 280 272.
-Custom dyno tune
-Tms pulleys and electric fan conversion
364.1 whp 287.8 wtq

Custom exhaust thread and dyno http://m3forum.net/m3forum/showthread.php?t=569086
Cams thread and dyno http://m3forum.net/m3forum/showthread.php?t=554439
Custom cf airbox thread http://m3forum.net/m3forum/showthread.php?t=595180
Why not to use after market bearings with surfacetreatments and /or increased clearance
http://www.m3forum.net/m3forum/showp...4&postcount=10

Last edited by HassanEido; Sat, Apr-28-2018 at 09:21:59 PM.
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Old Mon, Jan-15-2018, 07:50:57 PM   #2
Brian N
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Default Re: My Custom CF Airbox Journey Begins

Whoo hooo finally!
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Old Mon, Jan-15-2018, 07:53:51 PM   #3
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Default Re: My Custom CF Airbox Journey Begins

this is going to be a very interesting thread, can’t wait to see what you come up with, best of luck and thanks for sharing this and your exhaust project with us, true assets to the community
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Old Mon, Jan-15-2018, 07:59:39 PM   #4
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Default Re: My Custom CF Airbox Journey Begins

Good for you! Good luck and this will be fun to watch!
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/// 2004 SilberGrau M3 · Coupe · 6MT · slicktop · manual seats · zero options · JOURNAL
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·Evolve-R Alpha N · Evolve CSL CF Airbox · Eventuri Scoop · Supersprint V1 stepped 63mm · SS V1 S pipe 63mm + 200 cell HFC · OE sect 2 60mm · SS Sport 60mm
·Besian · RE pullies/fan delete · WPC rod bearings · GroundControl S/A (Koni/Eibach 440/525) + tall RSMs · TMS Camber & Subframe plates · SPC Adj alloy rear camber arms
·RE Trans Mounts · AKG poly SUB/DIFF 95a · SDW RTAB · Weighted ///M knob + UUC DSSR + delrin carrier bush · OE CSL trunk · APEX 75mm Studs
·Sportline 8S 18"x8.5/9.5" · MPSS 245/275 · Brembo 996 36/40 345mm CSL Textar FF & 28/30 328mm CSL ATE "D738" FF · CM brackets & ss/teflon lines
·Pioneer DEH-80PRS · Eclipse PA5422 · CDT HD-6 + WS-100i · CDT EX-530 · 8" Kicker

DD/Beater: 1999 Civic LX - Kenwood x998 · PPI 1600.4 · CDT HD-6 + HD-100 · CDT EX-530 · DVC 10"
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Old Mon, Jan-15-2018, 08:06:43 PM   #5
lmtfi
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Default Re: My Custom CF Airbox Journey Begins

What are you going to use for a mold?
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Old Mon, Jan-15-2018, 08:29:19 PM   #6
HassanEido
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Default Re: My Custom CF Airbox Journey Begins

Thanks guys! You support means a lot.
@lmtfi , I have two options, both of which will reuse part of the stock box.
I figure the underside is perfect and durable, and the backside (throttle body side) is perfect and holds the stock trumpets nicely which I also plan to re-use. These parts will be carbon overlayed plastic. The top part and intake side will be cut open, and a foam plug will be made as a form that I will use to wet lay cf over it, which would then be fused to the filter flange(also made from a foam form and wet laid cf over it to snuggly hold the filter) . I have a gsr box that I can use for measurements and to template the snorkel etc.
Thats my plan for the first iteration anyway.
I promised a couple of friends to recreate this for them too. For that I would create a fiberglass mold and infuse resin into dry cf under vaccum.. the latter being more time consuming but repeatable, the former being easier for a 1 off project.
I'll try to document the entire thing
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Mods:
-Custom CF airbox
-SSV2 catless headers, Custom 2.5" dual sec1, Custom sec2 2.5" dual with e9xM X pipe, SuperSprint Race inspired custom section 3..
-Cat Cams 280 272.
-Custom dyno tune
-Tms pulleys and electric fan conversion
364.1 whp 287.8 wtq

Custom exhaust thread and dyno http://m3forum.net/m3forum/showthread.php?t=569086
Cams thread and dyno http://m3forum.net/m3forum/showthread.php?t=554439
Custom cf airbox thread http://m3forum.net/m3forum/showthread.php?t=595180
Why not to use after market bearings with surfacetreatments and /or increased clearance
http://www.m3forum.net/m3forum/showp...4&postcount=10

Last edited by HassanEido; Mon, Jan-15-2018 at 08:35:07 PM.
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Old Tue, Jan-16-2018, 02:55:47 PM   #7
HassanEido
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Default Re: My Custom CF Airbox Journey Begins

So something arrived in the mail today...
IMG-20180116-WA0014.jpg More pics to come when I get off work
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Mods:
-Custom CF airbox
-SSV2 catless headers, Custom 2.5" dual sec1, Custom sec2 2.5" dual with e9xM X pipe, SuperSprint Race inspired custom section 3..
-Cat Cams 280 272.
-Custom dyno tune
-Tms pulleys and electric fan conversion
364.1 whp 287.8 wtq

Custom exhaust thread and dyno http://m3forum.net/m3forum/showthread.php?t=569086
Cams thread and dyno http://m3forum.net/m3forum/showthread.php?t=554439
Custom cf airbox thread http://m3forum.net/m3forum/showthread.php?t=595180
Why not to use after market bearings with surfacetreatments and /or increased clearance
http://www.m3forum.net/m3forum/showp...4&postcount=10
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Old Tue, Jan-16-2018, 03:33:40 PM   #8
BMWjunkie11
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Default Re: My Custom CF Airbox Journey Begins

Oh I'm tuning in to see how this turns out. Good luck with this!
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Old Tue, Jan-16-2018, 05:03:46 PM   #9
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Default Re: My Custom CF Airbox Journey Begins

popcorns!
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Old Tue, Jan-16-2018, 06:27:11 PM   #10
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Default Re: My Custom CF Airbox Journey Begins

This is awesome! Do you think this will cost as much as buying one?
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Discussing My Custom CF Airbox Journey Begins in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)