2nd Gen R60 Countryman R60 custom CAI - Prototype

Discussion in '2nd Generation: 2007+ R55 through R61' started by AWD_Rally, Jun 16, 2015.

  1. AWD_Rally

    AWD_Rally Member

    Oct 15, 2014
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    Working on something fun...

    [​IMG]

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  2. Nathan

    Nathan Founder

    Mar 30, 2009
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    Interesting. Please don't ford any rivers!
     
  3. AWD_Rally

    AWD_Rally Member

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    #3 AWD_Rally, Jun 16, 2015
    Last edited: Jun 16, 2015
    I'm not finished, and I live in So Cal. ;) This isn't my first rodeo. lol. If I need to drive in inclement weather that tube can be pulled out in less than 30 seconds.
     
  4. ScottinBend

    ScottinBend Space Cowboy
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    Awfully small filter...........
     
  5. AWD_Rally

    AWD_Rally Member

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    #5 AWD_Rally, Jun 17, 2015
    Last edited: Jun 17, 2015
    Thanks......

    It's a prototype... so not finished.

    It's a 3.5" flange on that filter merged into a 3" tube.
     
  6. AWD_Rally

    AWD_Rally Member

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    Did some measuring and readjusting to fit a better filter.

    I didn't want to spend $50+ on a filter that didn't fit, hence the foam filter as a temporary place holder.

    Picked up a K&N filter recently. Here's how it came out.

    R60 CAI V 2.2

    Tight fit, but it fit.
    [​IMG]

    [​IMG]
     
  7. Metalman

    Metalman Well-Known Member
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    Interesting Adam...... How does the exhaust sound? I went through your compilation....:D
     
  8. AWD_Rally

    AWD_Rally Member

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    It's got some grunt to it. I have a complete catless system. 2.5" downpipe, 3" exhaust, 2.5" dual exit pipes.

    Rear now has two magnaflow staright-thru race mufflers on each exit pipe now, and one 3" resonator in the mid pipe.

    [​IMG]

    Cell phone video. It doesn't really do it justice.
    https://youtu.be/-K9am86Ms2E
     
  9. Metalman

    Metalman Well-Known Member
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    I just watched your video.... Nice cracks and pops..... Any drone on the freeway at cruising speed?

    I didn't see a flex pipe section.... With the engine movement with acceleration, any issues with cracked welds yet?
     
  10. AWD_Rally

    AWD_Rally Member

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    There is some drone, but nothing too extreme. With a little music it's definitely tolerable for passengers. I enjoy the music of the engine. :p

    If i wanted to cut down the noise more (which I might), I could add one or two of the 3" style Magnaflow race mufflers in the mid pipe, and take out the resonator. Those mufflers area little beasts.

    This is the muffler on the exit pipes: Magnaflow 2.5" Race Series part ##14156.

    No issues as of yet, as far as welds go. The custom system has been on the car for about 8 months now.
     
  11. TheModFather

    TheModFather Well-Known Member

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    Any pic's of how the 3" exhaust is bent around the transfer case?

    I was going to fab up a custom exhaust for the Porker, but looking under it, that is the only problem area.
     
  12. AWD_Rally

    AWD_Rally Member

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    It's 2.5" DP, to 2.5" under the transfer case, then turns 3" after that.

    3" could fit, but it would be pretty low, maybe with a good solid aluminum under tray. Now I know why the WRC car runs the DP/exhaust over the trans, to under the car. :p

    Quick vid of how the intake/exhaust sounds cruising around about 20 minutes ago https://youtu.be/sXKnhBLlkOo
     
  13. AWD_Rally

    AWD_Rally Member

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    Here's how it looks... before it was finished.
    [​IMG]

    I want to cut down the 2.5" pipe and add more 3" in there. I know more can fit.
     
  14. TheModFather

    TheModFather Well-Known Member

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    Only thing I would change is that last bend, other than that it looks great!
     
  15. AWD_Rally

    AWD_Rally Member

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    If I could weld I would be more picky... lol. But I do agree.

    That's where I'm hoping I can start the 3" pipe whenever I get a chance to take it back in to the shop.
     

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