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The Civic Has Boost! – Intake R&D, Part 2: Prototype Development

We are moving along with the intake project! Last time, we talked about the stock system and our goals for this project. Now, we will show you our process for assembling a prototype that we can test and analyze results from. Let’s jump right in!

Once our engineers finalize a design, the proposed idea gets modeled in 3D modeling software. The next step is to make the idea a physical reality. We have an awesome machine called a waterjet that can cut almost anything with pinpoint accuracy using a mixture of high pressure water and abrasive material. We upload our design to the waterjet through computer software, “telling” it exactly what we want to cut. The machine takes care of the rest! We just sit back and watch as our prototype gets crafted out of a big sheet of any metal we place inside the machine – in this case, steel.

Prototype 2016 Honda Civic parts ready for the waterjet process
Prototype 2016 Honda Civic parts ready for the waterjet process
Prototype 2016 Honda Civic parts in the waterjet process
Prototype 2016 Honda Civic parts in the waterjet process

Once the parts are ready, we pull them out of the sheet.

Prototype 2016 Honda Civic parts after the waterjet process
Prototype 2016 Honda Civic parts after the waterjet process

Next, we arrange the pieces, prepare them for assembly and weld them together to form the prototype.

Final cut pieces for the prototype 2016 Civic intake
Final cut pieces for the prototype 2016 Civic intake
Welding together the parts to the prototype 2016 Civic intake
Welding together the parts to the prototype 2016 Civic intake
Finished 2016 Civic intake prototype after welding
Finished 2016 Civic intake prototype after welding

Pay close attention to the image above. It shows how we plan to use the stock fresh air duct we discussed in the last post. The front of the box with the opening is where the filter will gather cool fresh air. We wanted to have an enclosed airbox while still retaining use of the fresh air that is guided into the duct. This will ensure that most of the hot air from the cramped engine space is directed away from the filter.

Prototype box fully assembled
Prototype box fully assembled
Prototype box fully assembled
Prototype box fully assembled

What’s Next?

2016 Civic ready for intake dyno tests
2016 Civic ready for intake dyno tests

We have a working prototype ready for dyno testing. Stay tuned for the next update to see our results and what our performance gains look like! As always, thanks for reading!

-Diamaan

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