Stillen air to air conversion fabrication thread
 

Well, as some of you know, this is something that has been in the works for some time. I believe the first conversation occurred about two years ago, when I saw this supercharger kit for the first time. The time has finally come for me to work my magic, and improve on some of the engineering done by Stillen.

The tear down was rather simple and straight forward. Pull the front bumper off, remove the water/air cooler, hoses, water pump and some additional plumbing. Once all that was removed, it was time to install the
large air/air intercooler. This is the same intercooler core used on the Boosted Performance twin scroll turbo kits, but with a different end tank configuration. The core is capable of supporting 2,000cfm, so flow will never be an issue.

So step one, install the standard FMIC brackets from the BP twin scroll turbo kit, and mount the FMIC…rather simple:

http://i137.photobucket.com/albums/q...psv3clupqw.jpg

http://i137.photobucket.com/albums/q...ps2rpspxwo.jpg


The next big thing and my biggest concern with this set-up was the supercharger air intake. As it comes out of the box, a 3.5” to 2.5” reducer is used on the compressor inlet, which then goes to a 2.5” 90 degree aluminium
bend. That then goes to a Y and two small air filter. Knowing how little space there is, and me wanting to turn this in to a 3” intake, I figured it will be a challenge.

It actually went rather smooth. I used a 3.5” to 3.0” 90 degree silicone reducer, which was cut in such a way to allowed me to install it with the headlight removed (only 4 bolts):

http://i137.photobucket.com/albums/q...pstkmumdrv.jpg


Not much room to work with:

http://i137.photobucket.com/albums/q...psw0hi4paf.jpg



http://i137.photobucket.com/albums/q...psbwchjmuc.jpg


The improvement:

http://i137.photobucket.com/albums/q...pstcfptzln.jpg

3” tube hanging in front of the driver side bumper, ready for an air filter:

http://i137.photobucket.com/albums/q...ps0en7ksjb.jpg


http://i137.photobucket.com/albums/q...psdkcpznag.jpg


This configuration will allow for much better flow of air in to the supercharger. It also allows one to use a larger air filter, which is also a big plus. Should be getting some nice cold air in there now:

http://i137.photobucket.com/albums/q...psd4rm5eqz.jpg

With the intake out of the way, I was able to move on to the S/C to IC piping. That was rather straight forward. A couple of the plastic pieces between the two fans needed to be cut, as well as one fan support on each fan (there are 8 total per fan, so it is not a big deal):


http://i137.photobucket.com/albums/q...ps7wmxlg9s.jpg

With that out of the way, I was able to rout a 2.5” charge pipe all the way down:

http://i137.photobucket.com/albums/q...psmwg49rsq.jpg

From there, it was rather straight forward to get to the IC inlet:

http://i137.photobucket.com/albums/q...psiwplhxrk.jpg


http://i137.photobucket.com/albums/q...ps0d3dvqvp.jpg


http://i137.photobucket.com/albums/q...ps3v3oikrm.jpg


http://i137.photobucket.com/albums/q...psfwrniwym.jpg

Next step, getting that nice cold air to the TB’s. 3” 90 degree out of the FMIC, and through to the engine bay:

http://i137.photobucket.com/albums/q...psyb44lpb0.jpg


http://i137.photobucket.com/albums/q...psaupzcxin.jpg

Moving on to the Y section, which is where I finished the night off.

http://i137.photobucket.com/albums/q...pspew6ekgn.jpg

The plan is to install the MAF sensors in the 3” section of pipe just before the black coupler. This will allow for a proper reading of IAT’s, and will greatly improve the range of these sensors.






Some random shots:

http://i137.photobucket.com/albums/q...ps1spfdtje.jpg

http://i137.photobucket.com/albums/q...psj2gu616t.jpg



As it is built, with this air/air configuration, and a smaller pulley set. I don’t think 600whp is out of the ballpark with this kit. The head unit is certainly capable of pushing enough air, and now everything
around it will be able to support it. I will post some more pictures once I get back at this tonight.

This will be a game-changer for the Stillen guys. Very cool.

Nice work Sasha, Sub to see what happens here. :)

Man you got a lot done last night after I talked with you lol.

Super stoked for this to be done!

Not improve the engineering...

You mean, you use engineering Stillen didn't use to make this product.

Hhahah

Well he did keep the SC an manifold LOL

Dang dude did you even sleep? This went together quick. Looks nice. The way you routed the charge pipe is pretty unique.

I take it turning it down 90* wasn't possible?

So you will put 2 Mafs in one 3" pipe?

It will be interesting to see the pulley set needed to reach 600whp. This will need to push about 4-5psi more than anyone has found.

He used engineering that doesn't need CARB approval.

Yes, I worked till midnight. Just couldn't stop, it was going rather well.


Thanks, and turning the blower 90 degrees was not possible. You would end up going down and hitting the driver side radiator fan. This worked out much better, and the upgrade much simpler/easier. If I was to make this as an upgrade package, it would take about 5 hours to install...that includes a few lengthy beer breaks.

I love new ideas and especially if they are implemented!

Great Respect :tup::tup::tup::tup:

Ivo

Stillen can get a air-air system passed too, Stillen is a HUGE company. Their system is cheaper to produce.

I'm saying the air to water design is a TERRIBLE design. Especially when the contact point is on the manifold.

Is there a way to create a system where people can go back to their stock intake manifold and use a dual intake setup similar to your single kit?

subbed! gotta see if you can make 600 and make the Stillen kit reliable!!

Let me know when this new Air To Air upgrade is ready for purchase! :bowrofl: