Building a better BHAF...

[Hohn]

Well, here's something I would like to revisit.



I think there are a lot of guys like me who REALLY dislike an oiled filter element. Thus, we are forced to run the BHAF or stock filter.



But, as HP increases, the BHAF begins to get out of its league, or at least that's what I've been led to believe. I have no idea at what HP that BHAF starts to lose HP relative to other intakes, but the DD Jammer 2 turbo thread mentioned that the BHAF was down on HP relative to the AFEs at lower HP levels than many of us would like to run.



So how can we get the high flow we want with the high filtration?



One option is to look at big rig air filters. There's the Farr Ecolite that Mallinson has made famous for its 1500CFM flow rating (at 8" water!). But it's next to impossible to package this on a Dodge pickup, as the dimensions are much too large.





Enter the Donaldson PowerCore. This is the way I am trying to head



Why PowerCore? Well, packaging is much smaller. Dust holding is over TWICE what a conventional filter would hold. It's DRY. It filters at a 99. 99% efficiency rate. This compares the the top-rated AC filter from the air filter shootout that's been much-discussed on here and other diesel pickup boards-- only it flows a LOT more.



Donaldson is a VERY respected name in filtration.



So, I get to digging, and find a possible candidate:http://www.donaldson.com/en/engine/support/datalibrary/034267.pdf



Note that the flyer linked above lists applications that flow up to 1000CFM!! This is the model PSD12, I believe.



So, I'm in the process of getting specifics from Donaldson as far as packaging dimensions and outlet sizes. The flow is there, and so is the filtration.



I've examined a round POwerCore filter on a Freighliner M2 high hp (Cat C7) and it was about the size of a BHAF, but it had a 10" outlet and needed special adaptation to work on the M2 that made it a no-go for a CTD. Maybe someone else could make it work.



Anyway, I will post updates once I get more specifics on this new possibility. We can make the BHAF better!!



Justin

 

[Texas Diesel]

Good find! Looks like a good filter too, oil analysis would prove it's filtering claims (99. 9%).



Keep us posted if you find a 3" outlet model.



Thanks!

 

[nickleinonen]

i have been looking for a bhaf replacment with the powercore media, but i haven't been able to get a good cross reference list to do so [and donaldsons website kinda sucks for that] if you do find something that is 4" id outlet and close to the 10. 5"x10. 5" that the bhaf is, do let us know here...

 

[JCleary]

That looks sweet. I bet it's quiet, too.

 

[Hohn]

I may have a track on something.



Unfortunately, the outlet is 6", so I will have to adapt it to make it work.



Specs are 1000CFM @ 7"-8", 99. 99% efficient,



It's similar to a BHAF in dimensions: 13. 56"L (prolly a little tight), 11. 17" Diameter



I think I can make this work. It's not for an on-road applications, but the guys at Donaldson think this might work, based on the Duralite units we run known as the BHAF.



I spoke with a Donaldson engineer for almost an hour. I should have one in hand in a few weeks.





One last thing: The guys at Donaldson are toying with a PowerCore version of the Duralite series. That means a PowerCore with the exact same dimensions of the BHAF may be released within a year or so. Specs should be similar to the specs for the one-off listed above.



This is an exciting possibility.



Now, I just need Scotty to make a housing for it so it will get COOL air



Justin

 

[Matt400]

Interesting, I for sure would rather run a dry element and the noise suppression of this vs a BHAF would no doubt be way better including winter protection.



I was at a Ford dealer the other day in the parts department they were selling something that looked just like what you have there but was as direct replacement for a PSD. I will call and ask what it was.

 

[Hohn]

There is a Ford Motorcraft kit that is made by Donaldson for the Powerstroke. It uses the PowerCore media.



Maybe we could adapt this filter to the CTD? Based on what I saw of the Ford unit, it appears that the housing wouldn't adapt easily to the CTD. There are all kinds of sensor holes and stuff for all the FORD junk that is attached to the airbox.



I wanted something that was more of a universal filter like that BHAF is.



Oh, and this Powercore filter is waterproof



I hope this actually materializes instead of just being a great empty hope.



Justin

 

[Matt400]

Ok. . found it.



It's this one They need something for us!



#ad

 

[ECappleman]

Well, here's something I would like to revisit.

But, as HP increases, the BHAF begins to get out of its league, or at least that's what I've been led to believe. I have no idea at what HP that BHAF starts to lose HP relative to other intakes, but the DD Jammer 2 turbo thread mentioned that the BHAF was down on HP relative to the AFEs at lower HP levels than many of us would like to run.

Justin

Hmm, maybe I missed something but here is what was posted by KL,



"The testing we did was based on HP, not filtration or airflow. We tested the BHAF (which scored the worst HP, BTW), the K&N, AFE, RE-0880 (original Scotty airbox), all on a 600hp 12v. The AFE won. Beat the BHAF by 9hp, the others by less - but that's what we decided to carry - AFE. "



A 9hp loss at 600hp is not going to make me change from a filter that has proven to flow well and keep the Si lvls down. I check my turbo at every oil change ( removing the BHAF makes it so much easier to get at the oil filter) and have yet to find a smudge of anything on the blades.

 

[Matt400]

A 9hp loss at 600hp is not going to make me change from a filter that has proven to flow well and keep the Si lvls down.

I can agree with that. Noise suppression and winter protection is what would make me look at this idea. At 400-500hp it would even be less I am sure.

 

[Gary - K7GLD]

"but the DD Jammer 2 turbo thread mentioned that the BHAF was down on HP relative to the AFEs at lower HP levels than many of us would like to run. "



Well, I won't speculate on the power levels I *might* "like to run" - but down at the power level I *do* run, the BHAF doesn't seem to be much of a restriction or handicap! :-laf :-laf



BUT, I'm always on the lookout for something better (especially at the same, or LOWER cost), so keep us posted!

 

[Hohn]

See-- that's the thing. This Powercore filter would flow MORE air and filter as well, if not better. The Duralite BHAF uses a regular cellulose media, which is like 99. 6% efficient. The Powercore is 99. 99% efficient. So it flows more, AND it filters even better.



The real question to me is going to relate to cost. Given that a BHAF lasts so long and is relatively cheap, this PowerCore filter is going to have to be REALLY good to justify a higher price. Even if it IS much better, do we NEED something much better? And at what cost does it become not worth it?



It's not HP to me that's important, it's more EGTs.



The Powercore could potentially be a "lifetime" filter for many CTD owners. The thing holds a LOT of dust. We all know that a BHAF already lasts practically forever, even in dusty environments. Now imagine a filter that lasted twice as long.



While KL posted that they lost only 8 hp with the BHAF, I don't think that's the whole story. Was there any vacuum being pulled at the filter? If so, how strong was it? How were EGTs with one compared to the other?



Two last points:

1) The airflow of the Powercore is straight-through, not from the sides like a BHAF. I think this helps.



2) What if the main restriction is no longer the filter, but the 4" intake duct??? How about 5"?



jlh

 

[Hohn]

I can agree with that. Noise suppression and winter protection is what would make me look at this idea. At 400-500hp it would even be less I am sure.

I agree totally. The BHAF isn't necessarily costing us HP, at least not significantly at the levels most of us like.



But if I can improve airflow drastically AND increase filtration efficiency, why would I NOT do that??



It's not for everyone, it's not the be all, end-all. It's just something I would like to see become an option for us.



Besides, with M4s, I'm going to need more air than with the DD2s.



jlh

 

[Diesel&Donuts]

Now, I just need Scotty to make a housing for it so it will get COOL air

Justin[/QUOTE]



Why not make yourself a 4 1/2" hole in the cowl to get your cool air.

I had a Scotty II with good results but don't like to do the oiling. I'm getting a BHAF and plan on leaving the hole in my cowl to draw in the cool air (hopefully).

Harold

 

[jcarey]

JLH, how about a Reducing Hose Insert. Air Flow Systems has them. Online, they show a 5" to 4" max, but say they have other sizes.



http://shop.airflowonline.com/Merchant2/merchant.mv



Jim

 

[nickleinonen]

t's similar to a BHAF in dimensions: 13. 56"L (prolly a little tight), 11. 17" Diameter

dang, that is pretty big. . i don't think that could work on the 3rd gen's [at least not on mine with the filter positioned as i have on mine... ]

 

[Beast2B]

As a side note, I notice a 'WUFF-WUFF' noise (great description, huh?) towing heavy (17k +) uphill (5% grade +) at high boost (38psi +). I believe it is the restriction of the BHAF with the required airflow. My last two dyno's were run with the filter and inlet hose removed, and were (unscientifically but consistently) ~12hp higher peak. I can live with these consequences as long as the BHAF filters WELL. I like the AFE PG7 StageII, but not $250 worth! If a better alternative shows up, I'll be right there in line.

 

[Matt400]

I don't know if it helps research or not on this project but the kit for the PSD that uses a Donaldson PowerCore filter is Ford part #2U2Z-9k635-AA and the Motorcraft # is FA-1759. I don't know which PowerCore filter it uses though.

 

[swankmetal]

any updates on this one? definitely got my interest.

 

[Hohn]

I'm still waiting on the filter itself to arrive from Donaldson.



I'm not sure when it will get here, but I'd think that by the end of this month I could have something concrete.



jlh