Pipercross AirMax Carbon Fibre Intake System for Mini F56 Cooper S/JCW - PK454

Pipercross Airmax Carbon Intake System
Take your vehicle's performance to the next level with Pipercross Airmax Performance Induction Systems. Meticulously designed carbon induction systems are tailored to your specific vehicle, providing a bespoke solution for maximizing power, efficiency, and induction sound.

Pipercross Mini F56 Cooper S/JCW Airmax Lid Intake System
The Pipercross Airmax Lid 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).

KEY FEATURES

• Carbon fibre Airmax replacement airbox lid featuring
• Pipercross Plus premium, hybrid multi-density replacement high flow 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 confirm 85.37% maximum, 74.24% average airflow restriction decrease vs. full OE intake system
• 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. As such, the Plus filter serves as the foundation around which the rest of the Pipercross F56 AirMax kit is built, with all other intake components methodically designed to fully utilise this drastic increase in airflow performance.

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. All above functional performance improvements are combined into a single carbon-fibre unit that adds a beautiful form-and-function aesthetic to any applicable Mini engine bay.

REAR INTAKE PIPE (*Only inclcuded 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. Each pipe assembly is powder coated to similarly stringent specifications, for additional corrosion resistance and aesthetic appeal without any internal bore/boss overcoating (and OE component fitment issues associated with boss/bore overcoating).

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 environmental factors have no effect on the Pipercross kit’s function or aesthetic – no matter how hard the vehicle is driven. 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 replacment 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. Bench airflow testing was conducted on the full OEM intake system and multiple Pipercross prototype intake design iterations/configurations, using Pipercross’ in-house, custom designed and built airflow test apparatus inside a controlled environment. Performance testing of the OEM intake and final Pipercross intake design (in various configurations) was completed at a third party, independent, environmentally regulated dynamometer cell to ensure unbiased, final performance gain data was captured.

AIRFLOW TESTING DATA
Various intake configurations were tested on Pipercross’ in-house, custom built stationary airflow test apparatus. To develop an initial performance benchmark, the full OE intake system (complete OE airbox plus OE air filter, OE outlet hose and OE rear intake pipe) was flow tested to a maximum CFM value. The Pipercross lid, Plus filter and intake hose were then tested with the OE rear intake pipe – to quantify Pipercross AirMax Lid Kit. Finally, the full AirMax intake system (installed on the OE lower airbox) was tested to gauge the effectiveness of the complete AirMax system working in harmony.

The graph below summarize the results of this testing on all configurations detailed above, confirming the increasing performance benefits of the staged Pipercross F56 intake configurations. Of note is the performance gleaned from the AirMax lid and intake hose components – which yield 59.19% maximum/47.18% average reduction in airflow restriction. Additionally, the full AirMax kit was able to flow intake air up to 725 CFM, where the Pipercross AirMax Lid kit supported a maximum of 715 CFM, while the full OE intake system maxed out at 540 CFM.

PERFORMANCE TESTING DATA
Like the airflow testing; the staged intake configurations were tested on an otherwise unmodified 2016 Mini Cooper S JCW, utilising a roller-based dynamometer inside a temperature-controlled environment, at an independent, third-party testing facility. Each of these configurations was tested with both OE and aftermarket, stage 1 software tuning applied to the vehicle – to gauge the effectiveness of the various Pipercross AirMax configurations operating with both OE and aftermarket tuning. Additionally, all tests were conducted on the same day, within the same cell and the vehicle was allowed to cool between testing sets; to eliminate as many temperature-related testing variables as possible.

To develop an initial performance benchmark, the vehicle’s stock tuning was maintained and the full OE intake system (complete OE airbox plus OE air filter, OE outlet hose and OE rear intake pipe) was tested. The Pipercross lid, Plus filter and intake hose were tested with the OE rear intake pipe – to quantify the performance of the Pipercross AirMax Lid Kit. Then, the full AirMax intake system was tested to gauge the effectiveness of the complete AirMax system working in harmony. The full OE intake system was then reinstalled, stage 1 software applied to the vehicle and the above testing sequence repeated, to acquire data on all Pipercross F56 AirMax components working in conjunction with an aftermarket stage 1 software suite.

The graphs below summarize the results of the testing detailed above, confirming the significant performance benefits of the complete Pipercross F56 AirMax Intake system. Of note is the performance gleaned by adding the Pipercross rear intake pipe to the AirMax Lid kit (to create the complete Pipercross F56 Full AirMax Intake). This yields an additional 14.01% maximum/16.67% average WHP and 14.01% maximum/16.67% average WTQ gain over the AirMax Lid kit with stock software. Furthermore, integrating aftermarket stage 1 software tuning increases these gains to 70.53% maximum/52.31% average WHP and 32.03% maximum/35.63% average WTQ gain over the AirMax Lid kit, thus solidifying the performance benefit of the full Pipercross AirMax F56 Intake Kit.

STOCK SOFTWARE RUNS
 

STAGE 1 SOFTWARE RUNS