3d printed DIY intake mod and AFE intake review

Sharing some info and real-world results. I don't reference power, in my opinion, its next to impossible to feel a slight 10-15hp gain, and a DIY intake isn’t worth the cost for Dyno time. FYI when I talk about fuel efficacy, I have the 4x4, run 90 octane E-free on mostly rural roads, and obviously, its a reference to my driving style. The DYI intake part should be easy to adapt to the OEM intake box with good results.

I picked up the AFE intake on black Friday and I had some issues with the design and results so that triggered the DIY idea. The system overall is ok, with modest results. With the stock system, I was getting consistent at 17mpg after the intake 18 max 19 if I was mindful. The sound improvement was very small. You can only faintly hear the turbos spool and overall from the intake I was hoping for sound. Compared to other vehicles I added aftermarket intakes this was the least beneficial out of the box.

The AFE connecting flex couplers to the OEM tube are super cheap, much lower quality compared to stock. For the cost of the system, I was hoping for higher-end smooth reinforced silicone tubing similar to higher-end systems like my BMW has. This is probably just a personal annoyance with the system and will likely try to get a universal curved tube from HPS to replace it.

The missed opportunity from AFE is the auxiliary intake holes they add to the box. Good idea but they should have followed thru. Our trucks pull air from the fender which is good and all but with the air dam and opening being so high it really doesn't have any flow into the intake from that spot. The auxiliary hole AFE added is strangely behind the frame. I can only assume the hole was placed in that location not to get turbulent flow in the box or for air to flow back out (but I think that happens anyway in their system since the gain I had was so high)

So I added in cold intake from the in front of the radiator for direct flow to the box. Started with a 3d printed velocity stack tube with a clean connection angle for a nice install. The print allowed me to be more accurate in locating the intake end in the OEM air-diverting plastic. It's enough to be in the stream of air but set back not to obstruct flow into the radiator. Picked up $11 black flex tube 2.5” from Amazon, cut it in half to make 2, and ran it thru the frame opening behind the headlight. It's a tight fit but it does get thru without modifying anything. If you have the stock box I would recommend adding the intake hole right behind the opening next to the headlight for a straight run into the box. In my case, I needed to print 2 more adapters to get the tube in the tight angle behind the frame to the AFE box

After this DIY tube install, I had the improvement I was hoping for. I'm consistently over 20MPG and up to low 22MPG if I'm driving fuel efficiently and not listening to the turbos all the time. The sound improvement is so so much better. I can hear the turbos build pressure under moderate throttle even with the radio at a normal level.

Didn’t take it on the highway yet Toyota claims 24mpg. I speed so I'm not hitting that number stock, maybe with the new system. I don't mind selling the 3d printed parts for the cost of material and shipping, not an advertisement or sale post just send me a message if you are interested in trying to do something similar. should be easy to do without the custom parts i think it just makes it clean looking.

The white in the tube seam is super glue, I'm waiting on an upgraded 3d printer so I can use high-heat filament for my final print

 

I like this idea. I'm grabbing the TRD filters soon and will look into this mod once they show up. i'd love to get some more cold air in there. Nice idea and good execution!

 

Interested in seeing dyno numbers. Had a similar mod on my tacoma, didn't see any gains but it sounded cool.

 

What did you use for your prints?

 

If you want to hear turbo whoosh noises you need an open top intake. I run an S&B on my F150 Ecoboost and its no louder than the stock intake because its closed box but guys who run the open top system get tons of noise

I also got an AFE intake for my Lexus GX and agree that their couplers are completely lame. The quality of the intake is not up to par with my S&B for my F150 but cost $125 more for a less complex intake. I have also run AFe's intercooler on my F150 and it was a steaming pile of crap, but is probably the most expensive intercooler on the market for the F150. I bought a replacement from another brand that literally cost 1/2 the price and it blew the AFe completely out of the water in terms of IAT's. Honestly, unless I have no other option, I would not buy or recommend anything AFe. Its overpriced for what you get.

I also have a hard time believing Toyota would just leave 3-5 mpg on the table over an intake. If they could have picked up 5 mpg they would have made it happen to keep their fleet averages as high as possible. A couple of tenths on an mpg is one thing but they wouldn't have left 25% on the table to save $5 on intake parts.

I imagine what you might be seeing is your truck breaking in since its a 2023. I experienced a very dramatic increase in mpg's with my truck as I approached 5000 miles. When I first bought it I drove cross country and averaged something like 13 mpg, but now I can't get it anywhere near that low without a trailer behind me even with 35's.

 

I know there are a few people running the Trd filters. Has anyone actually posted mpg numbers before and after? I have always run k&n washable filters in my cars and trucks and the Trd ones are pretty much them. Just wondering because I’m looking for a few more mpgs and might wait a bit for some other intake kits to come out. I do feel like Toyota went with quite engine over fuller flow rates. Just curious on what people are seeing. I like the setup you used and how you improved it. Want to see the final setup when it’s done. my brother in Law is big into 3d printing and we have tweaked certain things to make them better and cleaner looking.

 

Are you going to replace the flex tube with smooth , formed tubing? The flex part being rippled causes alot of turbulence and restrictions. May help in this case but I dunno.

 

Trying to get my hands on some downpipes for the 3.5 TT. I know the Ecoboost guys have had some luck in terms of performance and sound.

 

THIS... toyota would not have left any MPG on the table, especially 5 with an intake. This stuff is comical, its their internal justification for buying snake oil noise machines

 

Downpipes are actually a ways down the list of mods for 3.5 ecos. You have to be pushing your turbos very hard to see any benefit, which means you would need an aggressive tune, which isnt an option on the Tundra.

Most of the tuners recommend other mods before downpipes(tune, intercooler, and even turbos.) Intakes are also generally not high on the list of mods on an ecoboost unless you are absolutely maxing out the turbos or making tons of power.

Also, with load based tuning like the tundra and ecoboost, you cant expect gains from mods because the PCM will just adjust for any improvements the mod may achieve. If an intake actually improves flow(which is questionable) then the pcm will either dial back boost or close the throttle plate to hit the target air load, eliminating any power gains. You may get a brief gain right after installing the mod as the truck has to learn and adjust trims to compensate, but it will not be long term

 

The other thing every one needs to realize about the intake and MPG is that the stock intake is not taxed at all under normal driving. Just like aerodynamic drag of the truck moving down the freeway increases as a square function of speed, so does the resistance of the intake. If you are just normally driving around, your engine is only needing to produce say 50-75 hp, or 5-7.5 lbs/min of air. That is nearly 1/6th of the air mass needed for WOT at 389 hp or 39 lbs/min of air. That means the air velocity is 1/6th the speed through the intake and is experiencing some significantly smaller fraction of the resistance. There would be effectively zero pressure drop across the filter in normal day to day driving.

in fact, my F150 Ecoboost has a pressure sensor directly after the air filter where a maf sensor would normally be located. I can data log ambient pressure against my intake pressure and know that I experience no pressure drop until very high flow rates. Even towing my travel trailer making 150hp doesnt induce a pressure drop across the stock intake.

Basically, the intake should have virtually zero effect in normal driving and only at very high flow rates would the intake maybe improve flow.

 

Are there any baffles to keep the rain out at highway speeds?

 

Planning on selling these? I've got an AFE kit and would be interested

 

The intake part is pointed down and about 45 degrees into the air stream. rain would have to get past the grille and go up, Ill check for water after the next rainy day but it would be pretty unlikely. this is also all pre-filer.

 

PLA for my working prototype at 230c. The printer ill upgrade to for the final version goes up to 350c, so the part would less risk for warping in an engine bay. final part may end up high-heat nylon or a mixed composite with carbon fiber.

 

I think Toyota goes for sound. I had a Tacoma before the tundra and only used a K&N filter with an HPS intake tube. I think I pulled another 4mpg out of it after the truck was lifted with mud tires. The factory intake tubes tend to be very inefficient with resonators, A lot of manufacturers are using non-removable charcoal filters. The tundra has something in the bottom of the factory box that looks like a charcoal filter. You won't get codes removing them and typical state inspections don't look for it but I'm not in Cali, that's a different world for inspections.

 

Since I do design work for a living I would say without a doubt that Toyota started the design with the chassis > engine > cooling system > turbos >ect and whatever negative space was left in the engine bay they said "that's the intake box" they didn't pull air from the fender as the best solution predefined design but as the easiest and cheapest solution for Toyota. They build production vehicles, not supercars. Only an aftermarket industry or race shop would redesign the same part over and over for the best performance results.

If I have time in a couple of months I can finish 3d modeling the box and intake and run a fluid-dynamic simulation to show the flow difference.

 

You are correct. I always crack up when I see someone saying their intake gave them better mpg. More colder air requires more fuel so it really makes no sense. Aftermarket intakes can increase power but you need a tune to take advantage of it.

 

you're also overlooking the basic function of the intake, cold dense air and additional CFM can improve engine efficiency and allows more complete burns. If the intake doesn't have air being pushed in it needs to vacuum out of the fender increasing work and reducing efficiency. When I get a JB4 I can monitor the mas, intake temps, and other sensors to see more info on what is happening for people that are looking for an explanation on how it's happening.

 

How you are gaining 25% in mpg? Yes id love too see the data. Toyota should hire you as an engineer if you turely managed to improve your mpg by 25% with $5 worth of parts

the air is ultimately going through two turbos and an intercooler. 2* difference at the intake isnt super meaningful. And again, at low flow rates like the truck is at under normal driving conditions, the stock intake isnt taxed.

 

ill get something to monitor post the data with it plugged and open. If anyone gives this a shot let us know if you notice any changes.

 

If you would like more testers. Post a link to your files for the prints maybe you'll get some others participating to help you make it better even.

 

that's not entirely how it works, cold dense air allows a more complete burn with less fuel. the computer can decide to dump more fuel in for the same burn. or you can give it a try and let us know

 

I can print for people, I had other motorcycle part designs stolen and sold for profit so I stopped sending the 3d files. in this case, you don't need the parts to make it happen. just run a 2.5" flex tube from the same spot to the box and if you see results pretty it up after or plug it.

 

These are great points and is something I also experienced while tuning and datalogging on another platform.

 

BINGO

 

I wouldn’t say it’s completely impossible, as I gained about an extra 2mpg on my previous Tundra (21) when I used the pedal commander throttle controller.

 

If Toyota left 25% mpg on the table over an intake tube then none of you should be buying their trucks because they suck at engineering.

I put a pedal commander on my 1UR FE lexue GX and gained nothing.

 

Yeh it wasn’t the reason I bought the thing, but using the city mode changed my mileage big time and it was a great surprise for sure.

Sorry you didn’t see something similar with yours. As I said it was an ancillary result for me, and likely why that’s not something they market as well. I also have two buddies who got PCs as well, one with a gen2 tundra who also saw a mpg increase and the other guy has a 17 Tacoma and he did not notice any change in mpg.