Design requirements for this intake were simple: The intake must not only be safe for the engine, but perform well both with and without tuning. The intake must be able to be installed quickly, without removal of the bumper. The intake must produce horsepower and torque gains throughout the RPM range, not just on the top end. Justification for the first is obvious, we want you to be able to bolt it on and go, without worrying about your air-fuel ratios and engine safety. Justification for the second came after installing other intakes, only to have our front bumper never fit the same way again. A little research showed that this was a common issue.
The design of this intake started with months of hands-on research. The entire development of the intake is chronicalled in great detail in GrimmSpeed's FT86Club thread where members helped with major design decisions. After the research stages and the determination that there was a gap in the intake market, GrimmSpeed got to work with design. Using the FARO Arm, GrimmSpeed was able to MAP the engine bay in 3D to ensure a perfect fitment. GrimmSpeed used that working envelope to maximise performance by eliminating the 90 degree bend just before the airbox. GrimmSpeed found that this contributed to decreased resistance, but also helped with accurate MAF readings.
GrimmSpeed placed the MAF sensor inside the airbox to ensure that the heat from the motor and headers didn't skew it's readings. With a solid theoretical foundation and a number of prototypes, our engineers hit the dyno. Working with a very well respected tuner, they tested 26 different intake configurations with over 140 dyno pulls. Armed with a massive amount of data, design decisions were made and we moved forward into production.