Flat 6 Motorsports - Macan Air Intake Development

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Flat 6 Motorsports has been hard at work to develop an easy bolt on solution to improve air flow to the turbos, thus improving turbo response and power output. Porsche provided an excellent cold-air delivery solution by leveraging ducts from the front grill that feeds air up through the hood and down into the air filter boxes. One area they left room for improvement on is the design in which air velocity can be manipulated to increase power. They split the air channels into two runners and placed a duct with a large area in the middle to drive the air flow into two chambers in the airbox. Because of this, they only put two filter surface areas to bring air in. This keeps air pressure high on the outside of the filter but slows the velocity at which air can pass through the filter and into the charge pipe leading to the turbocharger.

Design

After studying and analyzing this design, Flat 6 Motorsports developed a solution that was cost-effective and simple to install and service. The first principle was to increase the air flow in volume and in velocity. We achieved this by opening up the duct that connects to the hood to allow more air flow into the airbox. We then used CFD analysis to optimize the design of the air filter media. Advanced simulation software showed that a bell-horn like design would both maximize filter surface area and most efficiently distribute air flow around the filter which provides 360 degrees of material compared to just 180 degrees on the OEM filter. This design creates high-pressure on the outside of the filter while minimizing pressure drop inside the filter, causing an increase in stable high velocity air that leads to the turbocharger.

Materials

We chose to use the finest grade materials including a pre-preg dry carbon fiber with 2x2 weave to provide lightweight and stylish design to the top of the intake ducts. For the filters, we leverage a world-class supplier who's proprietary filter utilizes a synthetic multi-layer that does not use treatment or oils to maintain integrity. This technology enables maximum airflow with efficient filtration while reducing the need to service.

Installation

Installation is simple for this system which makes any able body the right fit for this DIY job. All that is required is simply removing 4 screws from the OEM top, removing the OEM filter and replacing it with the Flat 6 Motorsports High Flow Filter, then reusing the gasket on the Carbon Fiber Intake Ducts and bolting down the ducts to the OEM airbox. This job can be done in 15 minutes with a T-30 torx bit.

What's Next?

We are heading to production with the intake systems and expect to have them in-stock and ready to ship by the end of August. We will be validating the first production units on the dyno both completely stock and with optimized tuning leveraging the Cobb Accessport. More details coming soon including dyno results, photography and a video explanation.

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  • Jon Flat 6