Eventuri BMW E46 M3 Hybrid Carbon Airbox with/without Full Carbon Intake

BMW E46 M3 Hybrid Airbox

Performance Increase with OEM ECU tune: 20-22hp, 8-13ft-lb

Presenting a World first – the Eventuri Hybrid Airbox System, a breakthrough intake solution for the iconic BMW E46 M3. This system delivers the aggressive, race-inspired sound of the CSL Airbox with the seamless driveability and plug-and-play simplicity of a traditional intake. Until now, E46 M3 owners wanting the CSL airbox sound had to compromise on running the engine without the MAF sensor, often leading to expensive ECU conversions or remaps, where throttle response and driveability were negatively affected. Our Hybrid Airbox solves this problem and delivers the sound and power of a CSL airbox without the need for a remap, as well as the driveability and smooth performance delivery of a regular intake.

The Eventuri E46 M3 Hybrid Airbox System comes in 2 configurations, with and without the Eventuri intake. We are offering the airbox without the intake to allow existing E46 M3 owners with Eventuri intakes to be able to reuse their filter housing and scoop. The Hybrid Airbox system consists of a number of components engineered to perform a specific purpose and fabricated to the highest of standards. Here are the details for each component and the design ethos behind them:

The full Hybrid Airbox with intake configuration consists of:

• Carbon Fiber Main Airbox
• Carbon Fiber Airbox Snorkel with MAF tube
• Thermoplastic Molded Trumpets with Stainless Steel Reinforcement Rings
• Carbon Fiber Filter Housing
• Bespoke Dry High Flow Filter
• Carbon Fiber Cold Air Scoop
• Stainless Steel Brackets and Flanges
• CNC Machined Breather Adapters
• Custom EPDM Flexible Coupler
• Silicon Couplers
• Crankcase Breather Hose
• Additional Vacuum Tubing

MAIN AIRBOX ASSEMBLY

The Main airbox section houses the 6 trumpets as well as the breather system connectors. Made from prepreg carbon fiber, the airbox has been designed to resonate under load and produce the sought after CSL sound. One of the challenges of the construction was to ensure the long-term reliability of the interface between the trumpets and the airbox. This was resolved by using mechanical fasteners and gaskets to ensure an airtight seal which would not be affected by heat cycles and vibrations. A similar method was also used for the breather adapters.

The trumpets have been made with a glass fiber reinforced thermoplastic. The injection molding process ensures accuracy while keeping the inside surfaces smooth for airflow. This was more advantageous over making each one in carbon fiber as we can ensure perfect form for each trumpet with an accuracy not attainable with carbon. We also added CNC machined stainless steel rings to the trumpets to ensure that they do not deform when the silicon couplers are tightened onto them.

AIRBOX SNORKEL

The snorkel or lid of the airbox smoothly channels airflow from the intake to the trumpet area. This section also incorporates the MAF tube section where the OEM sensor is secured to a CNC machined MAF boss. The snorkel secures to the main airbox section using custom made screws which cut into plastic securing clips ensuring that they do not come loose under vibration.

CFD OPTIMISED The overall shape of the airbox was optimised over several iterations using CFD simulations to ensure the trumpets had adequate flow without suffering from starvation due to restrictions in geometry or turbulence.

INTAKE HOUSING ASSEMBLY

The filter housing comprises of our bespoke generation 2 filter, stainless steel bracket and the carbon fiber housing. The carbon pod shrouds the reverse mounted filter and smoothly shapes the airflow down to the plenum. This is a key feature of the intake design where we have removed the tortuous flow path of the OEM airbox and therefore reduced the pressure loss through the whole system. This also ensures that the airflow is smooth when entering the MAF tube section of the airbox to allow the sensor to operate without errors.

PATENTED TECHNOLOGY

Our patented filter housings have a smooth reduction in cross sectional area as they shroud the filters and taper down to the tubing. This geometry invokes the Venturi effect where the airflow accelerates whilst maintaining laminar conditions. It can be thought of as a large velocity stack. Our bespoke filters aid the airflow moving through the housings and allow for an even velocity profile as the airflow exits the housings.

COLD AIR SCOOP

100% Prepreg carbon fibre with a CNC machined collar - the air scoop forces ambient air directly into the filter opening. This scoop simply clicks into place in the front right hand brake duct and effectively saturates the mouth of the intake with cold air. It has been designed to take up half the height of the duct in order to allow airflow to still continue through the duct for the brakes. The scoop is so effective that even after a hard drive, the aluminium cowl at the mouth of the intake will still feel cold to touch.