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Discussion Starter #1 (Edited)
Mishimoto 2016+ Honda Civic 1.5L Turbo Performance Intake Development

The Civic Has Boost! Performance Intake R&D, Part 1: Stock System

As some of you already know, we have finally been graced with a brand new 2016 Honda Civic with the 1.5L turbo engine! We have planned our R&D process for the design of a performance intake and we are starting this project by dissecting the stock system so we can learn as much as possible. Let’s jump right in!

The Stock Intake



Honda has done an excellent job with their new Earth Dreams 1.5L motor. This turbocharged engine has a power output rated at an impressive 174hp, which is a nice amount of power for this new-age Civic. We are very excited about this chassis and we are eager to dig in and develop an awesome intake that will provide easy bolt-on power. Let’s check out some shots of the stock system on the car.







The intake has simple routing, but the system is more complex than you might think – we will get to that in a bit. You’ll notice that part of the intake piping is routed right over the turbocharger. In our design, we will opt to leave this part of the system alone so as to help with heat soak. Check out some images below.





Once we removed the desired pieces, we found a good amount of space to work with on our intake design.



Another pretty interesting design feature is the way that air is diverted to the intake. On the front driver-side part of the hood, a small rubber diversion plate is located right above the intake inlet. We had to be sure that this air diversion was indeed the purpose of this piece, as that is crucial to how we will go about designing this intake.





As we closed the hood, you can see in the shot above that the plate is placed right next to the vented area, which is empty space that air passes through. So, the air comes into that space via the front grille. Check out an image below that was taken from behind that area.



Let’s dive into the stock system components a bit more. Below is an image of the entire system.



The top half on the right is the intake where the air passes into the airbox. This is also the location of the air filter. The bottom half on the left is the resonator that attaches to the intake. It is more common in modern cars to have resonators incorporated in stock intake systems. They enhance the sound of the engine inside the cabin by means of specific frequencies.

Let’s see more in-depth images of these 2016 Honda Civic parts!







To wrap up this introductory post, let’s go over the goals we have set for this project.

Goals

Include a fully enclosed airbox

We want to be sure that this Civic is getting the coolest air possible. Since this is a very tight and compact engine bay, it is important that we keep things cool with this intake, so an enclosed airbox is a necessity.

Utilize the factory air duct
Utilizing the factory air duct is important here. There is already a design in place for directing fresh air into the stock intake, so why not make use of that in our design?

Replace only the top portion
The top half of the stock intake looks simple enough, however, removing the resonator was a complex task. We’d like to keep the resonator exactly where it is, which will keep the install easier and also reduce the number of parts that need to be removed from the car.

What’s next?

We will be designing and testing a prototype to see what kind of improvements we can make. Up next, our prototype design!

Thanks for reading!
 

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Discussion Starter #2
The Civic Has Boost! Performance Intake R&D, Part 2: Prototype Development

We are moving along with the intake project! Last time, we talked about the stock system and our goals for this project. Now, we will show you our process for assembling a prototype that we can test and analyze results from. Let’s jump right in!

Once our engineers finalize a design, the proposed idea gets modeled in 3D modeling software. The next step is to make the idea a physical reality. We have an awesome machine called a waterjet that can cut almost anything with pinpoint accuracy using a mixture of high pressure water and abrasive material. We upload our design to the waterjet through computer software, “telling” it exactly what we want to cut. The machine takes care of the rest! We just sit back and watch as our prototype gets crafted out of a big sheet of any metal we place inside the machine – in this case, steel.







Next, we arrange the pieces, prepare them for assembly and weld them together to form the prototype.







Pay close attention to the image above. It shows how we plan to use the stock fresh air duct we discussed in the last post. The front of the box with the opening is where the filter will gather cool fresh air. We wanted to have an enclosed airbox while still retaining use of the fresh air that is guided into the duct. This will ensure that most of the hot air from the cramped engine space is directed away from the filter.






What’s Next?



We have a working prototype ready for dyno testing. Stay tuned for the next update to see our results and what our performance gains look like! As always, thanks for reading!
 

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Great work, the 10th gen is getting love early in it's life, nice to see someone besides Injen......They are nice items too.
 

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Discussion Starter #4
Great work, the 10th gen is getting love early in it's life, nice to see someone besides Injen......They are nice items too.
Thanks for the kind words! We are excited about this intake as well. More updates are coming in soon!
 

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are you guys going to be making a drop in replacement filter for the stock intake? I've been used to going K&N but open to other brands on the market and you guys have shown to be right up their with the best.
 

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are you guys going to be making a drop in replacement filter for the stock intake? I've been used to going K&N but open to other brands on the market and you guys have shown to be right up their with the best.
Thanks for the kind words!

For this intake, the kit will come with our own conical filter replacing the components of the stock airbox. We currently have no plans for a direct drop in filter replacement for this Civic, but rest assured the filter we plan to use will be a high flowing one!
 

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Might just be best to get the full system from Mishi since you're going through all that effort already, plus the results will be noticeable, with that, rewarding. Used to do the same thing, just getting better OEM style filters but once you go for a full aftermarket air intake, you almost never stick with OEM with future cars.
 

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Discussion Starter #9
Might just be best to get the full system from Mishi since you're going through all that effort already, plus the results will be noticeable, with that, rewarding. Used to do the same thing, just getting better OEM style filters but once you go for a full aftermarket air intake, you almost never stick with OEM with future cars.
Thanks for the kind words. There are definitely benefits to using our design. With a fully enclosed airbox, your intake is getting cooler and fresher air. Also since it's located closer to the hood, hydrolock isn't even a concern! You'll also get more airflow with our larger filter. More updates coming soon!

Great post !
Very much appreciated!
 

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Can't wait to see the dyno chart and performance gains from the new intake!

I've read that manufacturers have tuned their cars to be much more conservative than the actual potential performance in an effort to prolong vehicle reliability. Will the increased performance from the new intake affect that?
 

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Can't wait to see the dyno chart and performance gains from the new intake!

I've read that manufacturers have tuned their cars to be much more conservative than the actual potential performance in an effort to prolong vehicle reliability. Will the increased performance from the new intake affect that?
Updates are coming soon!

The intake will not affect the tune in any way. Your air fuel ratios might sway towards the leaner side, but that is something you want to see from an intake. Leaner air fuel ratios means more air in the combustion process - which usually means more power! Hope this helps.

What kind of material was in mind for the filter box ? Progress looks great by the way !
Thanks! We will be using an airbox constructed of steel that will be powdercoated black. This will help keep the incoming air around the filter cooler and help shield unwanted heat.
 

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Discussion Starter #13 (Edited)
The Civic Has Boost! Performance Intake R&D, Part 3: Dyno Results

Here we have another update for our 2016 Civic intake project. This Civic has finally been put on our dyno to see how our intake performs – and we have some results to share with our Civic community! This car was tricky to dyno properly because of the continuously variable transmission (CVT), but no corners were cut during our testing. Let’s jump right in!




The CVT



Dyno testing a car with an automatic transmission is always a bit more complex than testing a manual transmission. The ability to shift the gears manually makes it a bit easier to set up a manual transmission on the dyno. With automatic shifting, however, finding an appropriate final gear ratio is not a simple task.

A continuously variable transmission (CVT), has a continuous range of effective gear ratios. The gear changes are more seamless than in a conventional mechanical transmission, which has a limited number of gear ratios. With a CVT design, the angular velocity stays constant, putting power to the wheels at a range of different speeds and with a higher efficiency than a mechanical transmission.

Because of the continuous change in gear ratios, we needed to adjust and reset our dyno to help compensate. We opted to record our runs within the 3,700 – 5,800 rpm range and within a gear ratio difference of 1.0. These settings allowed for the most accuracy possible in comparable and repeatable runs with this CVT design.


The MAF Housing

Generally, when designing the housing for the mass airflow (MAF) sensor, the inlet diameter should be as close as possible to the stock diameter. This allows the sensor to accurately read the increase of airflow while staying within an acceptable air-fuel ratio (AFR) that’s safe to run on a stock tune. This isn’t applicable to all vehicles; in some more sensitive engine ECUs, this increased airflow can result in a limp mode with self-adjusted ignition timing, fuel trims and throttle position. This situation destroys any potential for a power increase, so the MAF housing design going to be important.



Due to the proximity of the turbo and the radiator, we knew that the front section of the 2016 Civic intake pipe we planned to replace would need a precise design. Replacing this section with steel-reinforced silicone seemed like a great solution to help keep intake temperatures cool. We 3D printed the gray seen in the image above so we could get started with testing.

To find the most effective size for the MAF housing, we 3D printed multiple MAF housings of slightly different sizes. We first tried a MAF housing that was the same size as stock, but that yielded a loss in power. We then reduced the size to one millimeter smaller, and that put us back at stock power output.

This told us that reducing the size of the MAF housing might yield some power gains. So we reduced the MAF housing to two millimeters smaller than stock, and this is where we began to get some favorable results! Check out our graph below.



Our results were taken from an overall average of the runs we did on the dyno. We never use any single highest or lowest run, because that can wildly skew the results. As you can see in the figure above, we made some good power gains; the power increase was 9.38 hp and 9.67 ft-lbs of torque. We did lose about 1.5 ft-lbs of torque for about 150 rpm, but we suspect that this minor loss in peak gains resulted from the way the CVT behaved on the dyno rather than an actual power loss. Also, the gains in torque everywhere else along the power-band more than makes up for that minor loss! After the 4,500 rpm mark, we were able to keep the power above stock all the way to the end of the run, which is good for a smooth, consistent power gain for this 2016 Civic intake.

How about our AFRs? Check out our graph below.



This 2016 Civic intake will stay safe to run on a stock tune. We did lean the results out a bit, but this is to be expected, as more air is a sign that more power will be made.

How about a quick clip of what our intake sounds like on the dyno!

https://www.youtube.com/watch?v=8FcWMRdqvgc

The tone has improved with a more throaty and aggressive sound under induction. We know that this is an important feature for this car, so we took time to make sure the intake sound was up to good standards.


What's Next?



Now that we have some awesome testing results, we are ready to kick off our production process! Before we begin the stage of market production, we need to get a production sample of this intake to ensure perfect fitment. Once those pieces arrive at our facility, we’ll have an awesome update for everyone.

Stay tuned and thanks for reading!
 

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The Civic Has Boost! Performance Intake R&D, Part 4: Prototype Kit Components

We finally have all our prototype 2016 Honda Civic parts together for this kit. Let’s briefly examine everything we have so far, starting with the airbox.





As we discussed in the last post, we wanted to utilize the stock air inlet as much as possible, which is why we kept an opening at the top of the airbox. The remainder of the filter enclosure is protected within the physical box, to help keep out heat. The opening on the box where the mass airflow (MAF) sensor housing sits will be lined with weather stripping not only to prevent debris from getting inside, but also to secure the housing in place and absorb any flex resulting from engine torque.

The MAF housing looks really sharp! The cuts and edges on this piece are super clean, even though this is just a prototype unit. The MAF sensor will plug right into this unit. Check it out below!!



This prototype isn’t painted yet; the final version will be powder-coated black. Painted or not, this piece looks really great. Some nice features stand out on this simple piece, including the laser-engraved “AIR FILTER” at the top and the ever-so-slight venturi-style air inlet. A venturi-style inlet is a common feature on intake manifolds and throttle bodies. It simply means that the small, tapered opening at the entrance where air gets sucked in helps to increase velocity.





These awesome silicone hoses are reinforced with steel wire to prevent misshaping under induction. The silicone construction is beneficial when it comes to preventing heat-soak whereas an aluminum piece would pick up a bit more heat due to its proximity to the turbo and radiator.

Let’s check out more cool shots of the kit!







That just about does it for the majority of the R&D on this intake. The last thing we need to do before officially kicking off production is to confirm fitment on our 2016 1.5L T Civic loaner. Below is a shot of the entire kit, including mounting hardware and brackets.



The silicone intake hose will not only be limited to red. Like our Mishimoto 2016+ Civic 1.5L T Catch Can, we will offer the color options of red, blue, and black. Once we make sure everything fits perfectly, we can move forward!

Thanks for reading!
 

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any updates on this kit? Injen's intake claims to be gains of 29hp. do you think that was just the highest number and not an average like you are claiming? Can we see a pic of the blue catch can and silicone hose? i will be getting my EX-T in mid july and am planning on getting the catch can. may be also grabbing your intake as well ;) also is there any difference in leaving in the stock resonator or would it be alright to rip it out to install your system? one flaw i potentially see is when washing the engine bay or car in general, how will your kit prevent the filter from getting soaked in water during the wash? thanks! will you also be developing an exhaust?
 

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any updates on this kit? Injen's intake claims to be gains of 29hp. do you think that was just the highest number and not an average like you are claiming? Can we see a pic of the blue catch can and silicone hose? i will be getting my EX-T in mid july and am planning on getting the catch can. may be also grabbing your intake as well ;) also is there any difference in leaving in the stock resonator or would it be alright to rip it out to install your system? one flaw i potentially see is when washing the engine bay or car in general, how will your kit prevent the filter from getting soaked in water during the wash? thanks! will you also be developing an exhaust?
Great questions, and thanks for considering our intake kit!

We are currently working to figure out the logistics of exactly when we will finish initial production for these intakes. The good news is that the presale should be starting relatively soon, so be sure to look out for that!

This car is definitely still very new and there will be more competitors in this product category as time progresses. With that in mind it's important that we keep our center of attention on our products so we are positive they are the best that they can be. We try to go into projects like these with a fresh view to keep our expectations in check.

I can tell you that we offer some great benefits to our kit, such as an enclosed airbox that grabs air directly from the front of the car, so hydrolock should never be a concern. We will also use silicone to replace part of the intake tract and this will combat heat better than an metal section. Also, don't forget that we have a lifetime warranty on all of our products when we officially release them.

Here is what our catch can with the blue silicone hoses looks like in the engine bay:


Remember, our cans are all black, but the hoses have the color options.

We actually designed this intake with the resonator in mind. This intake has nothing to do with the resonator, it can stay exactly where it is, or if you are so inclined, you can take it out yourself! Just remember that it isn't necessary to do so since you can run this intake with the resonator on, it just won't be functional with our system.

With respect to washing your engine bay, I'd probably recommend taking the box and filter components completely out and then masking the silicone opening off to prevent any water from getting in.

I hope this helps!!
 

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I have to say, this entire thread is quite impressive, not often do you get to see what goes on behind the scene's like this, especially in the sort of detail it has been explained and outlined here.
Hopefully this way of sharing information continues with future products you guys plan to release.
 

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I love that they show progress steps. Makes the community feel like we're actually a part of what's going on. Overall this looks super quality. Very impressed with the way the MAF housing looks though !!!
 

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I have to say, this entire thread is quite impressive, not often do you get to see what goes on behind the scene's like this, especially in the sort of detail it has been explained and outlined here.
Hopefully this way of sharing information continues with future products you guys plan to release.
Very much appreciated guys! It's all about spreading the knowledge, we want everyone to be just as educated as we are when we develop these awesome parts. You can bet that any other projects that we may produce will be well documented every step of the way. Thanks again for the kind words!

I love that they show progress steps. Makes the community feel like we're actually a part of what's going on. Overall this looks super quality. Very impressed with the way the MAF housing looks though !!!
Thank you! That's precisely what we want everyone to feel. It's important that there is a feeling of transparency and inclusiveness, that hopefully keeps everyone more engaged. And I agree, the MAF housing is definitely pretty awesome!
 
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