We have started the development of an intake system for the C63 AMG. Initial research showed that the only aftermarket “intakes” for this platform consisted of larger duct feeds to the stock airboxes and drop in panel filters. Although larger cold air feeds are welcome, feeding the stock airboxes won’t release power as the same restrictions exist. Our aim is to redesign the airboxes and utilise our patent pending Venturi housings.

First Impressions

Taking apart the stock airboxes it is plain to see why no company has been able to replace them – complete lack of space! The space between the engine and bonnet is very small and there is a lot of heat generated in this area. Clearly this needs to be a sealed system fed by the ducting. Another interesting feature are the MAF tubes. Usually these are circular tubes but due to the shallow space available – Mercedes have used elliptical tubes which come out of elliptical exit tubes from the stock airboxes. This is going to be interesting!

Update October 2015: Initial Designs

Measuring the height between the engine and the bonnet we scaled down our housings to fit. The Since the housings are circular in cross section – we had to transition from circle to ellipse for the MAF tubes. Some 3D printed photos in place:

Finally to seal them we designed a transition from the stock duct tubes to the circular housing mouths. More 3D printed photos:

Initial Testing

With both sides printed we did some back to back testing against the stock airboxes. Results showed no gain in power which didn’t come as a surprise due to the small size of the housings and the small filter openings. Out of curiosity we tested the same housings that we have used on the Audi RS5 and BMW M4 systems. This time there was a decent performance increase – however, the housings were to large and you couldn’t close the bonnet. So – knowing that there is power to be gained we head back to the drawing board to package our Venturi housing technology into the space given!

Update 18-12-2015: Redesign

It is clear this will be a complete redesign with new style housings and even filters. The only way to increase the size of the housings and filters while remaining within the geometric envelope is to use elliptical filters and housings. Increase the width – maintain the height for bonnet clearance.

One of the advantages is that the MAF tubes are already elliptical so we can design the housings to exit into the MAF tubes without a change of shape.

Update 15-01-2016: Redesign 1

Elliptical housings and MAF tubes done: