Developing a MAF sensor housing for custom air intakes

[Daox]

As Darin and I have alluded to here and there, I've been working on developing a part for our Mirages. I'm starting this thread to show the development process because I think its fun and interesting. The part I'm developing is a stand alone mass airflow (MAF) sensor housing. It will be used for those of you who would like to make their own custom air intakes.

The OEM MAF sensor housing is molded into the airbox. If you want to make a custom air intake, you have to cut up the airbox to do so. A few guys have done this already, but a new airbox from Mitsubishi costs about $45 shipped to your door, and then you have to hack it up. The much easier solution? A custom MAF sensor housing that drops right in.

But, one can not make a custom MAF sensor housing without knowing the dimensions of the original, so I ordered one of the OEM airbox housings. Here are some pics.








As you can see, its not a horribly complex part, but its not super simple either.

Stay tuned for updates.



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UPDATE: I've made a 3d printed version of the MAF housing and they are for sale. More info here.

MAF sensor housing




MAF sensor housing - $29.99 shipped

[Daox]

The end result would be a piece similar in function to this:

[alex16]

Does this come with the lid? I want to modify my air box so that I can get a larger 2 to 3 inch pipe out and delete the stock inlet tube, I want the new inlet tube to be as close to the firewall as possible so I can build a hot air intake. With a larger diameter inlet tube it would also give that performance intake sound even with a stock filter, it would also allow me to use my stock air filter so I can keep receipts for warranty.

[namco]

Does this come with the lid? I want to modify my air box so that I can get a larger 2 to 3 inch pipe out and delete the stock inlet tube, I want the new inlet tube to be as close to the firewall as possible so I can build a hot air intake. With a larger diameter inlet tube it would also give that performance intake sound even with a stock filter, it would also allow me to use my stock air filter so I can keep receipts for warranty.

you don't need a 3" intake, not even if you turbo, its a waste of time/money. just do 2" pipe and a decent brand filter and you are good to go, even if you turbo.

also, they already sell 3" maf sensor housing at your local autoparts store, you can easily get one, the issue is once you install it, your stock maf sensor will be sending readings it cannot comprehend to the motor, causing drive-ability issues that will be notice. however, if you go 3" with a tune, it will run fine.

[Daox]

No, the lid is a separate number. I did not order it.

[Daox]

As I mentioned in our "What do you do?" thread, I'm a mechanical designer. I model parts in 3d and make drawings to get them produced. So, the next logical step for me was to model up the MAF sensor housing. This was a fairly quick process that I just did this past weekend. I took measurements of the airbox and transferred them to the model as accurately as I could. A lot was measured up with a digital caliper to ensure good accuracy.

When developing a new product like this, you have the opportunity to tweak certain things too which is always quite nice. In this example, I was able to make sure the outer diameter of the MAF housing was 2" on both ends. If you hack up the OEM airbox, the outlet end is 2" and the inlet end is 1.875". With this part, it'll be 2" on both ends for easier and more consistent sized connections.






So, the next step is figuring out how we're going to make these parts... Stay tuned for updates.

[alex16]

That looks awesome!

[Daox]

Thanks. Its quite a bit of fun designing car parts.

[Daox]

Any suggestions or guesses on how to make it?

[Tinker1980]

Any suggestions or guesses on how to make it?

Find a job shop/fab shop locally, try to find one with a tube laser. Give them a call, send that CAD drawing and ask for a quote.


If I had access to a tube laser I'd have that knocked together in 30 minutes. It would of course be metal, not plastic.

Actually...

Can you post a dimensioned drawing of that part? Especially the flange that the MAF sensor mounts to?