Building a better BHAF...

[nickleinonen]

hey hohn, did you snap any pictures of the element on its own??? looking at the shape of it [tapering towards the outlet] that might work in a 3rd gen with the way my piping is positioned... a little tweeking would be required in my piping, but i think it might fit maybe as it could come over top the alternator a little more as it is tapered... ???



hmm...

 

[Hohn]

First, I didn't use any expanding foam-- I just duct taped it. It's actually quite easy to bridge that gap, and it worked MUCH better than I expected it to. It doesn't leak at all, as far as I can tell.



The elliptical PowerCore filters are what I originally had in mind when I called Donaldson up looking for a possible BHAF improvement. After talking to their engineer for over an hour, he convinced me this was a better setup, because:



1) Air gets a relatively straight shot though the filter.

2) The elliptical filters are two-stage, and MUCH more restrictive. They are designed for mining and agriculture, not on-road. Think industrial here-- not performance.

3) the velocity stack feature of this filter enhanced flow potential as installed.

4) It should fit because a traditional BHAF fits.



Nick, I think that with the setup duct taped, it may in fact fit on a 3rd gen! I wish i had a 3rd gen to test it on or see if it worked.



I recently exchanged emails with Donaldson. They told me that they COULD do a 4" version, but it would NOT flow as well as the 6" version I am testing. The element moves so much air that anything less than 6" reduces the flow through the filter! Thus, we are now to the point where the OEM ducting is the largest restriction in the intake! Works for me



I also asked them a couple questions, which I am waiting for answers to. First, can i post a point of contact here so people can email Donaldson and get answers straight from the horse's mouth? How can we set it up to be tested on a 3rd gen?



I proposed to them that we try to get more of these out there and tested, ESPECIALLY on 3rd gen trucks. Since the fitment on MY truck is resolved to my satisfaction (I don't mind the tape), and since it could easily be adapted to any 2nd gen (as far as I can tell), I don't think the 2nd gens are a problem. 1st gen trucks aren't much of a market (small numbers), but there's so much space that I think installing one would be doable.



So it's the 3rd gen trucks that really need to have a solution with this filter. The tapered housing greatly helps with space issues.



If I get the go-ahead to post contact info, I'm sure they would like to have a 3rd gen tester!!



Finally, I proposed that my contact join TDR/DTR so that 1) he can best research the market, 2) he can find qualified, experienced testers, and 3) he can answer questions directly.



I won't hear anything back until Monday at the earliest.



Meanwhile, I love taxiing down my street and into my driveway



Justin



EDIT: No word on availability yet, as I think they are hoping to have a one-size-fits-all-CTDs solution before they market the filter. I would be surprised if this filter was a go-ahead before October.



I didn't take any pics of just the element. The element is glued to the tapered part, so it's not replaceable. Like a BHAF, you have to replace the whole thing if you want to change it. Removing the end cap (ring thing that's clamped on) will NOT help fitment in any meaningful way, as it just slides over the element to protect the sides.

 

[Tomeygun]

I wish i had a 3rd gen to test it on or see if it worked.



How can we set it up to be tested on a 3rd gen?



I proposed to them that we try to get more of these out there and tested, ESPECIALLY on 3rd gen trucks.



So it's the 3rd gen trucks that really need to have a solution with this filter. The tapered housing greatly helps with space issues.



I'm sure they would like to have a 3rd gen tester!!



Justin

ok,ok,ok. . Fine, I'll do it



Gotta take one for the team sometimes, ya know :-laf

Finally a BHAF for us 3rd gen smokers - you can imagine my excitement Oo.

 

[Matt400]

They told me that they COULD do a 4" version, but it would NOT flow as well as the 6" version I am testing.

True but a 7" will flow better than your 6" I am sure and so on...



From what I understand the one you have there is actually overkill for a 5. 9

If they did a 4" version and made the OD 9. 5" it would fit all Cummins equipped Dodges, problem solved.

 

[rbattelle]

If I get the go-ahead to post contact info, I'm sure they would like to have a 3rd gen tester!!

Hello!



-Ryan

 

[Hohn]

From what I understand the one you have there is actually overkill for a 5. 9

If they did a 4" version and made the OD 9. 5" it would fit all Cummins equipped Dodges, problem solved.

Can you verify this? If these dimensions are the silver bullet to a truly UNVERSAL CTD filter (that just happens to have insanely high flow), then I'm sure they would consider a slightly smaller version.



When I say universal, I mean from '89 to current. If so, then this could be the e-ticket ride to BHAF nirvana.



Besides, explain to me what's so wrong with overkill!

Justin

 

[JL penner]

I think to solve your problem, you need to quit thinking about trying to adapt the housing to the stock hose. It may be better for them to create a (or look for an existing) hose that will go from the 6" and taper down to the 4" turbo inlet.



What do you think



Btw, I would be interested in one of these, where do I sign up???? Oo.

 

[Matt400]

Nothing wrong with overkill as long as it fits.



As for the dimensions there are folks that have stuffed the Donaldson B105006 in a 3rd gen and that filter is 10. 5" OD but complain of a tight fit.

Another fella has used the Donaldson B085011 which is the 8. 5" version of a BHAF that fit much better.

Seems 2nd gen BHAF users have more room.



Just seemed pretty slam dunk for a 9. 5" OD with 4" connection to me.

I would think a power core like you have there but in the above size would connect up to OEM intake on a 3rd gen using a short 45 piece. probably would even fit using the popular torque tubes out there.



Length needs to be held as short as possible, and I am sure the one you have there is too long for a 3rd gen.

 

[Scrappy]

Don't forget me! I'll do it!

 

[nickleinonen]

the 10. 5x10. 5 bhaf element i have under my hood is a tight fit, but it fits well with how i have mine plumbed... i really don't want to downsize my element... with a paper element, downsizing could be ok, but how i see it with the powercore, all the flow is through the one end of the filter, so there is less surface area than in a standard bhaf, but the design of the filter media allows it to flow well and filter well... if donaldson had something that was 11" diameter and about 10" long that was tapered down to a 4" outlet, it would work as a drop in for how i have mine plumbed. .

 

[Matt400]

if donaldson had something that was 11" diameter and about 10" long that was tapered down to a 4" outlet, it would work as a drop in for how i have mine plumbed. .

Thats good to know, I didn't know there was another 1/2" to spare.

 

[Hohn]

Here's one thing I want to bring up: TWINS.



Most twins setups have a 5" inlet needed. Now, in terms of numbers, it makes sense to me to market a 4" outlet and not address the twins crowd. Right now, twins=oiled gauze filter. No way around it thus far.



But would it be feasible to see a 5" outlet version, and have people adapt it to 4" for their trucks? A Twins setup would REALLY test how much air this thing can move. Right now, a 35 or probably even a 40 can't test this filte much at all-- they simply can't move enough air.



How much restriction would there be using the 4" version on a twins setup? I think it would be unacceptably high.



Maybe they could make a 4" and 6" version??



It's just an aside. Since twins trucks are a relatively small percentage of the market, it doesn't make sense to me to cater to them at the expense of the vast majority that runs singles.



Am I whacked?



jlh

 

[Tomeygun]

Am I whacked?



jlh

based upon how far you have brought us with this mod thus far... . nope. . perfectly un-whacked



Really though, 5 inch inlet would be great, we can always use plan-b - duct tape!

 

[Matt400]

Only problem with catering to the twin flolks is the diameter will never be narrow enough to stuff down there on the frame rail where they mount the AFe's

 

[nickleinonen]

Only problem with catering to the twin flolks is the diameter will never be narrow enough to stuff down there on the frame rail where they mount the AFe's

there's always this...



#ad




:-laf:-laf:-laf



i don't like chrome though

 

[rbattelle]

If someone could come up with a way to plumb it, I would love to mount a semi-style air cleaner back on my headache rack.



-Ryan

 

[Duluth Diesel]

What's the latest?

TTT

 

[Hohn]

Latest is that a small number of 3rd gen owners have been brought into the loop for testing on 3rd gen trucks.



I simply can't provide Donaldson with 3rd gen info, so others have stepped in to help out.



My Duct tape is holding up well. No leaks. No dust in the intake tube. No sign of dust passage or any reduction in airflow. It simply moves all that the HX35 can demand. I LOVE IT!



I think that the airflow compromise of a 4" outlet over the 6" outlet is a small price to play for simplified packaging and more marketability.



If a 4" version could "drop in" even on a 3rd gen, we'd be set.



jlh

 

[tmacc]

Justin,

I would wrap your duct tape w/ the aluminum foil type of duct tape to really keep a seal. Heat does a number on cloth "duct tape". BTW thank for the research.

 

[Hohn]

Funny you mention the foil tape. I just taped over the outside of the ducting, the filter, and the connecting point. I decided it might be a good insulator (somewhat), so I got a little crazy and taped up my intake horn and some other things, lol.



jlh