Building a better BHAF...

[Duluth Diesel]

Do you think there would be a better, and shorter, way to get that thing down to 4 inches. That would allow a little more room and still let us use the stock intake tube without the kink. I bet if you wrapped some rubber around the housing, it would vibrate less on the fender. Perhaps cutting up an old inner tube and wrapping/zip tying it on? I like the way this is going. I'd like to see it tweaked a bit to allow it to install as easily as the BHAF.



Great work Hohn!!!!

 

[Matt400]

the element is NOT paper, and it IS water-resistant.

Thats neat!

 

[Hohn]

Do you think there would be a better, and shorter, way to get that thing down to 4 inches. That would allow a little more room and still let us use the stock intake tube without the kink. I bet if you wrapped some rubber around the housing, it would vibrate less on the fender. Perhaps cutting up an old inner tube and wrapping/zip tying it on? I like the way this is going. I'd like to see it tweaked a bit to allow it to install as easily as the BHAF.



Great work Hohn!!!!

Why do we want to keep the factory intake tubing? IMO, the fact that it's designed to flex a bit, and has RIBBED sides makes it a huge restriction. What does it say about the intake tubing that I can have this kink in it and STILL notice improved airflow?? Maybe it's not the weak link with the stock filter setup, or even with a regular BHAF, but with THIS filter, I think it's definitely hurting things more than it would with a lower-flowing filter.



j

 

[Matt400]

You need a flex coupling when mounting the filter off the engine due to the movement of the motor mounts under power.

Mounting the oval unit on top of the valve cover with intake facing the left fender would allow for a rigid pipe but as you said, they don't make that flow/filtration combo in the oval.

 

[Hohn]

Couldn't you use a PVC setup with Rubber adapters or something to accomplish a smoother intake hose will still allowing just enough flex? The stock setup isn't really that flexible, though it appears to be very restrictive.



jh

 

[Duluth Diesel]

Good point about the ribbed flex tubing being restrictive. I guess its a lot like using flex duct on a forced air HVAC system. The ribs DO cause a restriction. So a smooth, alumnium pipe joined with rubber fittings that allow some flex would be better, much like is commonly seen with twin turbo setups. This is good stuff! I like the brainstorming! The only problem I see with PVC is for those of us who see extremely cold temps in the winter, combined with the vibration of the CTD, could cause the PVC to crack or shatter and allow the turbo to ingest plastic shards.

 

[I SPEED]

This thing is so cool!!

I've got to get one. Also thinking there has to be a way to run from 6" to 4" without the PVC (and kinking the factory tube).



Hats off to Justin #ad
#ad
#ad




Is it my understanding that your local Donaldson retailer cannot order this part?

Please let us know if we can order direct.

 

[Matt400]

Justin- you mentioned this one flows 1000 cfm, do you recall what the Duralite BHAF flows?

 

[Beast2B]

how about an intake tube from some plastic composite? ... or make a form/mold and use carbon fiber for the finished product. attach it to the turbo with a flexible connection for a little give.

Justin, could you carve the lip off of the large end of the housing for a little more room (and maybe a little less angle at the attachment to the stock intake tube)?

Have you had a chance to see how much room you have now between the hood and the housing? if you could prop up the open end at all you could eliminate some of the pinch in the tube

 

[Scrappy]

the inlet tube for the second gens is smooth on the inside, it's just ribbed on the outside to make it stiffer. I cut the tube apart in the middle of the bend and added a piece of 4" tubing to get my BHAF to sit like I wanted it to.

 

[Hohn]

Justin- you mentioned this one flows 1000 cfm, do you recall what the Duralite BHAF flows?

450CFM @ 6" water, as posted by AK RAM on DTR.

 

[Hohn]

the inlet tube for the second gens is smooth on the inside, it's just ribbed on the outside to make it stiffer. I cut the tube apart in the middle of the bend and added a piece of 4" tubing to get my BHAF to sit like I wanted it to.

Good point about the intake being smooth. So maybe I just need something that fits a little better?



There's VERY little room for the hood to close, so propping it up isn't really an option. There's no room to carve ANYTHING off. The filter housing tapers to a 6" outlet. Then I have the black reducer on there to get it down to 4" (note the pic-- the part with the hose clamps is the reducer). The filter does NOT come with that reducer, it's a Lowe's item. If there were a way to reduce it without adding 3" of length, the filter would fit perfectly, with no kinks in the OEM duct.



I've considered the possibility of ditching the reducer and instead inserting the OEM duct inside the filter and sealing it off with expanding foam sealant. Not sure how that would work, but it would fix the problem for sure. It also means changing the filter or separating it from the OEM ducting becomes a real problem, hehe!



Custom plumbing using some kind of composite would be cool, but then this is no longer a hardware store bolt-in affair. I wanted us to have something better than a BHAF that was still REASONABLY easy to install. Meaning, you don't need custom parts, just hardware store or home center type stuff.



jlh

 

[Hohn]

OH-- and I emailed my Donaldson rep to find out where it can be bought, and how much the MSRP would be...



jlh

 

[Hohn]

OK, here's the hiccup, and why you won't find one at the Donaldson Dealer. From an email:



Justin,

Just another note of clarification; the unit we sent to you was actually an experimental modification of the P/N PCD100028 used in a compressor application. A silencer plate was removed from the original unit to eliminate as much restriction as possible for your application. If this were to be released to production for automotive use, a new number would have to be assigned for your version, and depending on the potential qty. , the outlet tube could be modified to reduce right down to a 4" outlet to eliminate the need for a 6" to 4" reducer adapter that you describe as a challenge to fit in.



So, this is STILL a prototype. It's not yet for sale. Donaldson has some internal handoffs to make before this can become a reality. The division that should be selling them to us is their Commercial Automotive division. My rep was NOT from that division, and while he has been VERy helpful, he can't legally sell me something.



Oh well, I'll keep working on this and let you know when/if it's coming to a Donaldson dealer near you.



jlh

 

[I SPEED]

OK, here's the hiccup, and why you won't find one at the Donaldson Dealer. From an email:



Justin,

Just another note of clarification; the unit we sent to you was actually an experimental modification of the P/N PCD100028 used in a compressor application. A silencer plate was removed from the original unit to eliminate as much restriction as possible for your application. If this were to be released to production for automotive use, a new number would have to be assigned for your version, and depending on the potential qty. , the outlet tube could be modified to reduce right down to a 4" outlet to eliminate the need for a 6" to 4" reducer adapter that you describe as a challenge to fit in.



So, this is STILL a prototype. It's not yet for sale. Donaldson has some internal handoffs to make before this can become a reality. The division that should be selling them to us is their Commercial Automotive division. My rep was NOT from that division, and while he has been VERy helpful, he can't legally sell me something.



Oh well, I'll keep working on this and let you know when/if it's coming to a Donaldson dealer near you.



jlh

Patience...



I do like the idea of it being produced with the 4" outlet. We'll just have to wait to see if it ever makes production.



The big question is... Do you have to return the prototype or can you keep it?

 

[Scrappy]

why not put twins on your truck and then you would only have to reduce it from 6"to 5"

 

[Matt400]

450CFM @ 6" water, as posted by AK RAM on DTR.

I did some searching since I posted that question and found the OEM filter is 452 and the NAPA BHAF #2790 is 680.



It's too bad Donaldson doesn't have something like what you got there but just a little smaller so fit isn't such an issue. I would think 600-700 CFM should be plenty for most.



I wonder if on a 3rd gen it could be mounted in the OEM spot with the element pointing at the hood and a 90 on the bottom. Then a NACA Duct could be added to the hood but you would have to figure out a water drain/baffle.

 

[Hohn]

Patience...



I do like the idea of it being produced with the 4" outlet. We'll just have to wait to see if it ever makes production.



The big question is... Do you have to return the prototype or can you keep it?

Well, they haven't asked for it back, yet-- and I don't plan on reminding them, lol.



Right now, I just have to convince them that there's HUGE market for dodge diesel intakes, certainly enough to justify a market leader like Donaldson exploring it.



I told them that a version with a 4" outlet would all but eliminate any fitment problems, as the total space taken up (i. e. volume) would actually be less than a BHAF. Losing the reducer gives you back 3" or so of critical length.



It would be nice if we could have ONE filter that would fit all CTDs, regardless of year. Would a 4" version of this filter do it? It would probably be very close.



For now, I'm gonna run this with the kinked hose and see how it does. I won't really know more until I get some kind of box back on the truck and can open it up quite a bit.



The MACH 4s will be here in a week or two, and then we'll REALLY see how this filter works on an HX35 at the outer limits.



jh

 

[Hohn]

I did some searching since I posted that question and found the OEM filter is 452 and the NAPA BHAF #2790 is 680.



It's too bad Donaldson doesn't have something like what you got there but just a little smaller so fit isn't such an issue. I would think 600-700 CFM should be plenty for most.



I wonder if on a 3rd gen it could be mounted in the OEM spot with the element pointing at the hood and a 90 on the bottom. Then a NACA Duct could be added to the hood but you would have to figure out a water drain/baffle.

The flow numbers we posted are probably at different pressure differentials, so they probably aren't a 1-on-1 comparison.



CFM need to have pressure drop with it to be meaningful. Just like a 600cfm carburetor can flow over 850 CFM, it will just draw a partial vacuum in doing so (restriction exceeds 1. 5 inches).



justin

 

[I SPEED]

Right now, I just have to convince them that there's HUGE market for dodge diesel intakes, certainly enough to justify a market leader like Donaldson exploring it.



jh

I wonder if hearing from other CTD owners would help the situation? Having you tell them how big the market for this application is one thing, but hearing from those here and on DTR, etc. . would be quite another.



Just a thought.