42 Draft Designs has long avoided the crowded air intake marketplace. In order
for an intake project to captivate our attention, the goal must be difficult to
achieve. With the TT 180hp as our platform, we set out to create a high quality
intake with a clean look that truly delivers. Although the process was far from
simple, the finished product exceeds our expectations with
ease.
Our High-Flow Intake System
combines an oversized air filter with an engineered velocity stack in an
accurately shaped heatshield. Precision machining, fabrication, and finishing
methods are used throughout. The result is an air intake system that delivers
serious gains and looks the part.
To understand how it works,
lets take a look at the construction. Starting at the MAF, an adaptor slides
over the MAF while a silicone o-ring creates a seal. Our velocity stack slides
through the heatshield and attaches to the MAF adaptor with an o-ring seal. The
velocity stack represents the heart of the intake, drawing air equally from all
sides and accelerating it to the opening of the MAF. An oversized air filter
properly fits the velocity stack, minimally restricting airflow. The heatshield
represents the backbone of the intake, holding the components together, mounting
to the engine bay, and shielding the filter from engine bay
temperatures.
The entire system assembles
and installs with perfection thanks to the extensive craftsmanship used to
create each component. The MAF adaptor and velocity stack are CNC machined from
6061 aluminum. O-ring grooves are utilized and contours follow the OEM MAF
flange. The heatshield is constructed from waterjet cut 304 stainless steel.
Each piece is fitted and TIG welded on precision tooling to assure accurate
fitment. The heatshield is finished with a satin black powdercoat and stainless
steel hardware is used to assemble the components.
Installed in the engine bay,
our intake appears oversized and robust. On the road, our intake unleashes power
and sound. The sound created by the velocity stack can only be described as
vicious. Substantial power gains can be felt throughout the power band with no
loss of low-end torque.
We set out to create a
serious air intake system and we're confident that we've succeeded. To learn
more about our High-Flow Intake System, follow the tabs
above.
-
CNC Machined 6061
Aluminum
-
CNC Waterjet Cut
304 Stainless Steel
-
TIG Welded
Construction
-
Silicone
O-Rings
-
100% Stainless
Steel Hardware
- Satin Black
Powdercoated Finish
FITMENT NOTES:
- Fits 1999-2006 Audi TT 1.8T 180hp FWD and Quattro
-
Fits OEM &
Aftermarket Turbo Inlet Pipes
-
Retains Factory SAI
Plumbing
- Reversible - No
Modification Required
- Does NOT fit 225 TT models.
No
Silicone.
Eliminating the use of
silicone couplers was an important goal for this project. Although silicone
couplers get the job done, we saw two major drawbacks and decided to avoid them.
The first lies within the coupler itself. Smooth transitions are key to the
function of a velocity stack and proper MAF readings. If the MAF is connected to
the velocity stack with a silicone coupler, a series of edges inside the coupler
create turbulence which can counteract the effect of the velocity stack. We find
that a smooth, shallow transition from the velocity stack to the nose of the MAF
produces the most power. The second drawback is all about appearance. We think
silicone couplers look messy, so we decided to machine a MAF adaptor that allows
the MAF to slide into and bolt to our intake. The photos above and below show
our CNC machined MAF adaptor and how we achieved our goal of no
silicone.
6 Inch Aluminum Velocity
Stack.
The purpose of this project
was to develop an intake that delivered serious power gains. In order to achieve
gains beyond a simple cone filter we designed a velocity stack to augment the
intake airstream. Our velocity stack draws air from a 18.85" perimeter,
accelerating and evenly distributing the air molecules across the inlet of the
MAF. This methodical distribution of airflow from a larger area to a smaller
area results in higher atmospheric pressures within the intake airstream and
more accurate MAF readings. An overall increase in efficiency delivers power
gains throughout the power band. Other intakes typically deliver top-end gains
and low-end losses. Thanks to our velocity stack, our high-flow intake system
delivers power from idle to redline. The photos above and below show various
angles of our CNC machined velocity stack.
Massive 6 Inch Air
Filter.
To compliment the airflow
characteristics of our velocity stack a serious filter is needed. We chose a
K&N filter with a 6 inch inlet and a 6 inch overall length. The shape of
this filter allows our velocity stack to draw air equally from the sides without
additional steps or turbulence. K&N filters were chosen based on their
excellent reputation and proven performance. The photos above and below document
just how massive this air filter really is!
Precision
Fitment.
Precision fitment is the only
fitment we offer. From o-rings to mounting brackets our high-flow intake system
is built to fit like an OEM accessory. Starting with the MAF, our MAF adaptor
follows the exact contour of the MAF flange, seals the nose, and allows the MAF
to bolt to our intake system. The velocity stack slides through our heatshield
and attaches to the MAF adaptor with a silicone o-ring seal. The heatshield is
CNC waterjet cut from stainless steel, bent and TIG welded. Waterjet cutting
gives us accurate shapes and repeatable fitment. Our mounting brackets are
perfectly positioned to fit without bending or modification. Air filter
placement is no accident. Precision placement of our velocity stack within the
heatshield allows the air filter to install without touching the heatshield.
This ensures the air filter will never be "banged-up" like other intakes. The
photos above and below highlight the details and the overall fitment of our
intake system.
Complete SAI
Hardware.
Many intake systems fail to
include proper secondary air injection hardware. Most include a filter and a zip
tie leaving the installer to "figure it out." That approach is not good enough
for our customers. To address the loose SAI tube we machined an adaptor which
allows the installation of a small filter. This adaptor clicks into the SAI hose
like a factory connection. No modification to the factory hose is necessary
making this upgrade completely reversible. Our adaptor allows the connection of
a filter with a 1" inlet. The filter we include is visibly larger than most SAI
filters. This larger filter allows the SAI pump to breathe, keeping it quiet
when in use. A stainless steel rubber lined clamp is included to support the
assembled tube and filter.
The
Details.
If you haven't noticed, we're
obsessed with detail. We believe the quality of a product is only as great as
the sum of the details. Our high-flow intake system is no exception. From the
overall fitment down to the milling marks on the aluminum, we've left nothing to
chance. Take a look at the detailed machining that lightens the velocity stack.
Every edge is finished and chamfered. Take a look at the heatshield and notice
how the cutouts allow the machine work to shine. This intake system is loaded
with detail from top to bottom. The photos above and below highlight a few
interesting details.
42 Draft Design is a manufacturer of high performance parts and accessories for VW, Audi, Porsche, and BMW vehicles. From exhaust and intakes to custom catch cans and billet aluminum engine parts, 42 Draft Designs covers it all and prides themselves on never cutting corners, always delivering the best possible products to enthusiasts.
42 Draft Designs products are manufactured from scratch in Millersville, MD. We use high-quality American-made materials throughout our products, manufacturing in-house every component possible. When necessary to outsource, we start with American companies that manufacture their products in the USA. Our modest manufacturing facility is staffed by a team of 12 machinists, metal fabricators, and TIG welders trained to work in exacting precision. From design to manufacturing we never rush, cut corners, or take shortcuts.
Due to growing demand for our products, lead times may exist.
Most items with a lead time are considered 'Made To Order' items and are subject to an early cancelation fee and a restocking fee if returned.
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