Welcome to our new blog!
Here we'd like to share more detailed information on our research and development efforts and share with you as much detail as we can on the R&D process for the parts we make.
We'd like to be as transparent as possible so anything we can share as we develop product we will share with you here as it happens!
Let's start with our new 2021 Hyundai Elantra N-Line Intake system!
The new Smartstream 1.6T engine is something we've never seen before so with this came some new design challenges. One big thing that restricted us in our freedom to create the best intake possible was this vacuum distribution junction just behind the air filter. See figure 1 below.
This vacuum junction is fixed in 3D space because of the OEM hard plastic lines that run to it. We have very little wiggle room so we have to design our intake around this variable. With that being said, we 3D scan the engine bay and the OEM intake to create the design environment in the computer. See figure 2 below.
With the OEM components properly located, we started making the new system. Our new intake's main principals are having the largest tubing possible while having the shortest track possible and keeping the OEM connections in place including that vacuum junction and bypass valve recirculation hose position. See figure 3 below.
Our new system features a huge 4in air filter with velocity stack that feeds a 3.5in carbon fiber tube that connections to the stock turbo inlet. Our large and smooth tubing ensures pressure drop between the air filter and turbo is reduced which allows the turbocharger to spin easier. Looking at the screenshot above, you can see the OEM vacuum line junction in silver/yellow located in the exact same place as if the OEM intake was installed. The same goes for the bypass valve hose connection. If you want the ultimate protection for the air filter, the system is available with an airbox that feeds fresh air directly from the grille. See figure 4 below.
Now we dyno test all of our parts to make sure they do as we intend. In newer cars (especially from Hyundai/Kia) they create already pretty efficient intake systems along with programmed power limiters in the computer. Sometimes an intake system addition will not add power because of these limiters. We have seen it on the previous generation 1.6T engines.
So for initial testing, we will 3D print some of the new components to combine with existing brackets and air filters. See figure 5 below.
We had to create custom attachments for the OEM vacuum junction and bypass valve connection. You can see the OEM lines are hard plastic and fixed in there connection positions. See figure 6 below.
With the test parts installed, we test drive and load the car on to the dyno. See figure 7 below.
