Pipercross AirMax Carbon Fibre Intake for Audi 4.0T C8 RS6/RS7 - PK457

he PK457 Pipercross AirMax Carbon Fibre Intake System takes your Audi 4.0TT C8 RS6/RS7 to the next level. Meticulously designed carbon induction systems are tailored to your specific vehicle, providing a bespoke solution for maximizing power, efficiency, and induction sound.

Pipercross Audi C8 RS6/RS7 AirMax Intake System

The Pipercross AirMax Intake System has been designed and engineered to directly replace the OEM Audi intake airbox lid, air filter and turbocharger inlet hoses on the C8 RS6/RS7 with the 4.0TT engine.

KEY FEATURES

• Carbon fibre AirMax replacement intake airbox lid featuring 61.39% increase in outlet area
• Pipercross Plus premium, hybrid multi-density replacement high flow panel filter
• Step-matched, thick-walled silicone hoses, designed to maintain OE engine flexure and clearances
• High-tolerance, hard-anodized aluminium standoffs and carbon-bonded baseplate for long-term durability
• Flow tested to confirm 90.70% maximum, 81.35% average airflow restriction decrease vs. full OE intake system
• Power increase upto +14 - 39WHP & + 16 - 42Nm Trq gains (Stock to Stg1)

OEM INTAKE ASSESSMENT

The OEM intake system on the Audi 4.0TT engine (found in the C8 RS6/RS7 vehicles) showcases a suite of performance-focused design queues that have come to be expected from Audi’s RS level vehicles. These design aspects allow the OE intake system to properly support the 4.0TT engine’s airflow requirements in almost all situations, when the engine is operating with OE engine tuning/software. Conversely, this same OE system begins to demonstrate shortcomings when aftermarket engine tuning packages are applied - particularly given the significant performance potential of the 4.0TT engine with aftermarket tuning (and the resulting drastic increase in engine airflow demands).

The OE intake filtration medium, airbox outlet sizes and upper airbox internal volume were all identified by the Pipercross engineering team as potential opportunities for intake airflow improvements. However, the lower OE airbox half (and subsequent panel filter shape/size) as well as the OE turbocharger inlets were found to be sufficient for the notably increased airflow targets; based on OE RS-tier performance design efforts, specific part size/functionality and Pipercross engineers’ experience with overall performance intake design across a multitude of engines/chassis.

PLUS PANEL FILTER

Pipercross’ flagship panel filter; the Pipercross Plus, serves as the performance core of the C8 RS6/RS7 intake kit. This filter implements a hybrid, bespoke filtration foam stack-up to achieve the optimal balance between increased flow and air filtration. Additionally, the Plus filter range feature an industry-first, CNC-laser cut, 0.9mm thick aluminium backing frame that increases effective airflow 22.1% over typical steel mesh backing frames. The Plus filter was benchmarked against the OE pleated panel filter via airflow testing inside the complete OE intake system. During this testing, the Plus filter significantly outperformed the OE panel filter - reducing airflow restriction by an average of 38.66% (and a maximum of 47.47% at 200 CFM). As such, the Plus filter serves as the foundation around which the rest of the Pipercross AirMax kit is built, with all other intake components painstakingly designed to leverage this drastic increase in airflow performance.

AIRBOX LID

The Pipercross C8 RS6 AirMax Lid compliments the drastically increased airflow potential of the Plus panel filter. Utilising the latest 3D scanning and CAD technologies, the AirMax lid was thoughtfully designed to achieve more post-filter internal volume - maximising the available engine bay space below the bonnet without compromising OE fitment/clearance standards. Similarly, this same technology was employed to increase the outlet sizes of the lid, yielding a 61.39% increase in outlet internal cross-section vs. OE. Both geometric features were tied together utilising the latest CAD technology; integrating these features into the Pipercross part with flow-conducive geometry to aid in the formation of laminar intake flow and further increase flow throughput from within the AirMax system. All functional performance improvements are combined into a single carbon-fibre unit that adds a beautiful form-and-function aesthetic to any C8 RS6 engine bay.

OUTLET HOSES

The Pipercross RS6 AirMax outlet hoses supplement the performance advantages of the AirMax lid and Plus filter. In addition to accommodating the larger outlets, the Pipercross hoses also eliminate the flow-destabilising flex convolutions of the OE hoses (as well as some competitor hoses). These convolutions create large flow instabilities on the interior boundaries of the convolutions, resulting in a smaller effective cross-sectional internal area (and less air thru-flow, as such). Step-matched OE turbocharger inlet hose connections are also featured on the Pipercross hose, further stabilising internal airflow and maximising internal hose airflow area.

DETAILS

The subtle details and ancillary parts of the Pipercross AirMax Intake Kit are what elevate it to the level of a premium product. The AirMax Lid features an integrated aluminium baseplate bonded to the carbon lid. This bonded plate ensures a consistent airtight seal to the panel filter. Aluminium structures are bonded into the AirMax lid outlets to ensure long-term structural integrity of the outlets to combat repeated mechanical/thermal load conditions. All stainless-steel hardware is provided with the AirMax kit (as well as aluminium flared mounting standoffs) to ensure corrosion, oil and other adverse engine bay environmental factors have no effect on the Pipercross kit’s function or aesthetic - no matter how hard the vehicle is driven.

RESEARCH AND DEVELOPMENT

All Pipercross products are designed in-house, utilising the latest 3D-printing, 3D-scanning, CAD, CFD, airflow testing and performance testing product development technologies. Multiple stages of testing were conducted within Pipercross’ engineering department, to gauge the effectiveness and shortcomings of the OEM system, while confirming the increased performance of various iterations and stages of the Pipercross AirMax intake. Bench airflow testing was conducted on the full OEM intake system and multiple Pipercross prototype intake design iterations/configurations, using Pipercross’ in-house, custom designed and built airflow test apparatus inside a controlled environment. Performance testing of the OEM and final Pipercross intake design was completed at a third party, independent, environmentally regulated dynamometer cell to ensure unbiased, final performance gain data was captured.

AIRFLOW TESTING DATA

Three intake configurations were tested on Pipercross’ in-house, custom-built stationary airflow test apparatus. To develop an initial performance benchmark, the full OE intake system (complete OE airbox plus OE air filter and OE outlet hoses) were flow tested to maximum values. The Pipercross Plus filter was then installed in the OE system, to gauge the resulting airflow increase from only the Plus filter. Finally, the full AirMax intake system (installed on the OE lower airbox) was tested to gauge the effectiveness of the AirMax lid and outlet hoses. A 722CFM vs. 934CFM maximum airflow capability (Full OE vs. Full AirMax Intake) was recorded.

The table and graph below summarize the results of this testing and serves to confirm the performance benefit of both the PX Plus filter alone, as well as the supporting AirMax components in addition to the Plus filter. Of note is the performance gleaned from the AirMax components - which yield 43.23% maximum/42.69% average airflow restrictionover the Plus filter alone.

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