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Metamorphosis - Stage 1 (Chapter 1)

As mentioned in the previous feature, Project R will now undergo some bolt-ons to improve performance, drivability, and increasing the overall fun factor whilst maintaining reliability. As mentioned earlier, the Integra Type-R is a brilliant car from the start, but why stop there when there's much much more to be had. For one, the car has already seen 5 years of life since it rolled off the production line in Japan. Though the mileage is low, the wear and tear of parts have already begun in motion. It is well known that Honda engines are hot engines, and especially in a tropical climate, that doesn't bode too well for parts like hoses, wires, sensors and other electrical devices. Did some looking around and almost instantly a solution was found. 

Cooling off with Thermo-Tec

Increasing Breathing Capacity...

Stock factory airboxes and their filters are designed to meet international emissions standards and regulations and due to this, most of it are restrictive units that robs the engine of its true potential. It is significantly true in the case of Honda K-Series engines which has a very air hungry nature. Increasing the overall intake surface area by adding in a larger airbox and filter frees up the hidden horsepower and torque and the Mugen unit is something to behold. It resembles the stock airbox in terms of design but that is where the similarity ends. As shown in the pictures below, the stock airbox has a small cone filter which is limits air suction in the mid-to high RPM range especially when the VTEC is engaged.

Mugen Airbox Vs. Open Pod Filters

For Project R, my choice of intake was narrowed down to either a Gruppe M Carbon Fiber Intake kit, the Mugen Airbox, and open pod filters from Blitz. Most open pod filters have loud, sporty induction notes and very impressive dyno figures, with gains up to even 10 WHP. Most however fail to see that Honda K-Series engines are exceptionally hot engines and whilst the dyno test is being done, the hood is popped up for cooling purposes, hence the impressive HP figures. On the open road, especially when driving during the day, more often than not the engine's performance will suffer a great deal from the problem of heat soak. Heat soak affects the Air / Fuel readings, which in turn creates erratic performance. Some may add in a stainless steel / aluminum heat shield but that itself does not help by much as it is not a completely sealed unit 

My choice this time is a sealed airbox system in the guise of Mugen. The airbox is larger than the stock unit and it itself acts as a heat shield from excess engine heat and given the fact the the Integra's engine bay is rather compact, with the stock airbox sitting smack in the middle of all the heat between the engine and the exhaust headed, my decision was simple. No open pod this time around. It'll be a good trade off for the induction roar for a milder sounding intake rather than sacrifice performance, response and drivability. 

"Unlimited Power" Airbox

Mugen High Performance Intake Systems incorporate all critical design criteria and as a result they fit perfectly, provide maximum torque and horsepower across the entire RPM range, and allow the driver to experience the engine note without being overpowered by extremely high sound levels. Pressure loss is reduced by the box design as this FRP Air Cleaner Box will duct fresh air directly from the front of your vehicle. The Mugen filter element supplied is of high quality and the element cross section is designed to reduce air resistance for maximum flow and response. 

Mugen states an increase in flow of 30% and temperatures being reduced by 10 Degrees C. The filter box itself is produced from high impact resistant black fibreglass re-enforced plastic (FRP) and is an attractive design featuring the Mugen logo. The Mugen filter element supplied is of high quality and the element cross section is designed to reduce air resistance for maximum flow and response. There will be a slight increase in induction noise with this item but if you like that Naturally Aspirated sound then it may be a bonus. 

Its relatively a lifetime use air filter. Just buy yourself a K&N Air Filter cleaning kit and when the time comes, just unscrew the 14 screws holding the airbox tight, remove the filter and clean it yourself.

The mechanics at Kaitenaz Racing proceeded to install the Mugen airbox in place of the stock unit. As the engine bay space was already at a premium, it did take some time for them to adjust the airbox for it to sit properly in place. The rest, as they say is history.

QMAX Nano Air

In the process of installing the Mugen Airbox, i was recommended by Kaitenaz Racing to try out the QMAX Nano Air. It a black,  rectangular device with honeycomb holes and has two clips to attach it to the air filter. It is supposed to streamline and breakdown air molecules to improve combustion and assist in providing better fuel consumption and also improve throttle response. QMAX Nano Air is a good helper for energizing air particles as it would make particles more active and smaller, converts more helium, increasing total burning surface area, helps gas burning in engine, increasing burning effectiveness, with sufficient helium would result in sharper suction, decreasing stopping distances. It is also designed protect engine from wear and tear, with minimal amount of accumulated carbon, increase engine life expectancy, decrease maintenance coast and makes for more complete combustion. 

• Increases horsepower and torque to lower carbon waste in engine.
• Improves braking to reduce stopping distance.
• Maintenance free, easy installation.
• Guaranteed to work over 250 thousand KM's.

Driving Impressions

The moment when all the nuts and bolts, screws and washers were securely fastened into place, I fired up the engine and revved it for a bit. I was impressed with the induction note. It does not have that sonorous growl associated with open pod units, but boy, it sounded just right. Took it for a short drive and it just blew me way. Response and revs climb faster, and it really shines when the VTEC is engaged. From 6,000 to 8,500 RPM the car just rocketed away as a few fractions of a second were reduced in the process. It felt like the beast was being unleashed. Initially I was a wee bit worried about the low-end response, especially when de-throttling and picking up speed from where it left off due to a much larger amount of air flowing into the combustion chamber. However, it did not falter one bit. Engine has become more free-revving, throttle is lighter and you don't have to push too much to get the power and torque out. 

The Thermo-Tec Thermo Flex did its job well. The air conditioner runs colder even on hot days and at night its so cold that most of the time, I just switch off the air conditioning. Power steering is slightly lighter right now. Can't say much for engine performance, but I personally believe that it will help a great deal when it comes down to lowering temperatures of the wires, which in turn translates to better distribution of electrical signals which then tentamounts to an overall smoother driving experience.

In A Nutshell...

I was duly impressed with the products that were installed in this segment. Not only did they work like a charm, it gives me assurance now that reliability is improved thanks to the Thermo-Flex heat shield sleeving which was designed to protect wires, hoses and other electrical devices. The air cond has run consistently cooler now, and I do believe the wires harnesses have a longer lifespan thanks to the Thermo-Flex's job in rejecting heat and lowering temperatures in the process. 

The Mugen airbox definitely ranks among the top of performance bolt-on mods in my book. A brand new one costs an arm and a leg but if you can, source for a 2nd hand unit. There are quite a number good conditioned ones going up for sale in the market and it works just the same as a brand new one. However, please check on the condition of the air filter and make sure the pleats are not bent out of shape and that there are no holes in it. Clean it thoroughly and re-oil it whenever you buy a 2nd hand unit. If money is not an option, by all means, buy a spanking new one fresh out of the carton box. I settled for a used unit because, as mentioned, this project is aimed at getting the best bang for the buck, to maximize performance for minimal cash. The Mugen airbox really unleashed a good chunk of hidden performance of the Type-R and made it perform the way it should perform. 

So far, the car feels much better in the performance aspect. When not pushed, its smooth, the induction note is silent and laying in wait. The moment I floor the pedal, there's this high-pitched whine, very much like a supercharger spool coupled with a sporty roar that comes in unison and both will sing their symphonious notes all the way till it reaches a crescendo. My Type-R now tells me to drive it harder, to push it further as the engine refuses to quit just there. It always says, not yet, not now, push the revs past 8,000 RPM and then shift gears. It is an addiction when it comes down to driving the Type-R in its current state, but will become more addictive in the coming days and months.

Up in the next feature, a complete lubricant change that will bring performance a notch higher, and then some.

Thermo-Flex

Dragstar Car Performance Center

No. C-1, JALAN PJU 1/45,
Aman Suria Damansara,
47301, PJ, SELANGOR D.E.

TEL : +603-7880 4804

MYR 100 / Box X 3 Boxes

Cost: MYR 300

(USD $ 85)

Airbox for Integra DC5 Type-R

Purchased 2nd Hand

Cost: MYR 1,200

(USD $ 340)

QMAX Nano Air for the Mugen Panel Filter 

8, JALAN PJS 11/16,
BANDAR SUNWAY,
46150 PJ, SELANGOR D.E.

TEL : +603-5635 5351

Cost: MYR 98

(USD $ 28)

Labor and Installation Charges

8, JALAN PJS 11/16,
BANDAR SUNWAY,
46150 PJ, SELANGOR D.E.

TEL : +603-5635 5351

Cost: MYR 50

(USD $ 15)

This Feature Segment's Total Expenditure:

 MYR 1,648

   (USD $ 468)

Prev Feature: Getting It Right!

Next Feature: Liquid Gold