Pipercross Airmax F56 Mini Cooper S/JCW Carbon Intake Kit

PRODUCT DESCRIPTION

The Pipercross Airmax Intake System has been designed and engineered to directly replace the OEM BMW/Mini intake airbox lid, air filter and intake hose on the F56 2.0T (B48).

FEATURES

 - Carbon Fibre AirMax replacement airbox lids
 - Pipercross Plus premium replacement panel filter
 - Step-matched, thick-walled, larger diameter silicone hose designed to maintain OE engine flexure and clearances
 - Stainless Steel hardware for long-term corrosion protection
 - Flow tested to 85.37% maximum, 74.24% average airflow restriction decrease vs. OE
 - Up to +7HP (Stock) to +16HP (Full kit Stg1)
 - Up to +8Nm TQ (Stock) to +16Nm TQ (Full kit Stg1)

OEM INTAKE ASSESSMENT

The OEM intake system found on the F56 2.0T (B48) Mini vehicles, features a unique blend of performance-focused design aspects, coupled with a multitude of compliance-driven features that would be expected of a high-volume, widely popular production Mini/BMW chassis. The OE intake filtration medium, OE upper airbox, OE hose flex convolutions and rear OE intake pipe (specifically, the integrated sound suppression system) were all identified by the Pipercross engineering team as potential opportunities for intake airflow improvements. However, the lower OE airbox half (and subsequent panel filter shape/size) as well as the OE front air ducting were found to be sufficient for Pipercross’ increased airflow targets. This determination was made based on existing OE intake features, specific part size/functionality and Pipercross engineers’ experience with overall performance intake design across a multitude of engines/chassis.

To accomplish the Pipercross intake performance goals, filtration media was to be improved via Pipercross’ unique, premium Plus panel filter. Both the upper airbox lid and rear intake pipe were to undergo a complete redesign. The redesigned Pipercross lid was to utilise traditional carbon fibre manufacturing methods to achieve the larger internal post-filter volumes and improve internal flow geometry; both required for the Pipercross kit’s performance targets. Similarly, the rear intake pipe was to be wholly replaced by a mandrel-bent, constant diameter aluminium pipe assembly – to eliminate the severely restrictive integrated OE sound suppression chamber.

PLUS PANEL FILTER

Pipercross’ flagship panel filter; the Pipercross Plus, serves as the performance bedrock for the Pipercross F56 Mini AirMax kit. This filter implements a hybrid, bespoke filtration foam stack-up to achieve the optimal balance between increased flow and air filtration. Additionally, the Plus filter range feature an industry-first, CNC-laser cut, 0.9mm thick stainless steel backing frame that increases effective airflow 22.1% over typical steel mesh backing frames. During developmental airflow testing, the Plus filter’s aluminium backing plate geometry and hybrid foam media was found to significantly outperform OE pleated panel filters.

AIRBOX LID

The Pipercross F56 Mini AirMax Lid pairs perfectly to the Pipercross Plus filter; supplementing the drastically increased airflow potential of the Plus filter. Utilising the latest 3D scanning and CAD technologies, the Pipercross Lid was carefully crafted to gain significant post-filter internal volume without compromising OE fitment/clearance standards. Similarly, this same technology was employed to integrate a billet aluminium MAF sensor provision into a flow-stabilised area of the Pipercross part (also with the same internal cross-sectional area as the OE lid, at the sensor location), to ensure correct MAF readings and resultant engine operation. Both the increased post-filter volume and MAF sensor provision were combined into the overall Pipercross part with geometry favourable to internal airflow - to aid in the formation of laminar airflow post-filter and further increase air throughput from the AirMax lid.

REAR INTAKE PIPE (*Only included in Full Kit)

The Pipercross F56 Mini rear hard pipe assembly compliments the benefits offered by the AirMax lid and Plus filter, elevating the performance of the Full AirMax kit to the next level. The Pipercross part accomplishes this by wholly replacing the OE composite turbocharger inlet pipe, drastically increasing airflow capability via the elimination of the OE split-chamber sound suppression system. The Pipercross assembly is constructed of larger 76mm (vs. 70mm OE) outer diameter aluminium tubing, offering even more airflow capability increases from this modest size increase. This aluminium tubing is CNC-mandrel-bent for a consistent cross-sectional inner diameter throughout. To guarantee OE-tier sealing of relevant OE components, both Pipercross vacuum connectors and the turbocharger inlet connector were designed and located utilising Pipercross’ in-house 3D scanner, then CNC-machined from aluminium rounds to rigorous dimensional/finish standards. Similarly, the Pipercross mounting bracket design/placement was extracted from this same 3D scan data; to mirror OE pipe mounting angles and clearances exactly.

SILICONE HOSE

The subtle details and ancillary parts of the Pipercross F56 Full AirMax Intake Kit are what elevate it to the level of a premium product. The silicone intake hose features a smooth internal bore, flow-matched coupling transition and 5-ply wall construction; yielding just the right amount of flexure without any of the airflow destabilization associated with OE convoluted flex sections. Designed to work with both the OE back pipe and the upgraded pipercross pipe (*Full kit only).

FITTING HARDWARE

All stainless-steel hardware is provided with the AirMax kit to ensure corrosion, oil and other adverse engine bay conditions have no effect on the Pipercross kit’s function or aesthetic. Precision machined standoffs that house the fixing screws were designed to mimic the same spacing as the OE lid for perfect fitment and compression of the Pipercross Plus panel, featuring a counter sunk top section which neatly houses the replacement screws.

RESEARCH AND DEVELOPMENT

All Pipercross products are designed in-house, utilising the latest 3D-printing, 3D-scanning, CAD, CFD, airflow testing and performance testing product development technologies. Multiple stages of testing were conducted within Pipercross’ engineering department, to gauge the effectiveness and shortcomings of the OEM system, while confirming the increased performance of various iterations and stages of the Pipercross AirMax intake.