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Old 26th July 2007, 06:29   #1
EaglEye
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Installing Cosmos Racing 540 intake on M5?

I haven't done any measuring, but just eyeballing it it would seem to me that there's a possibility an intake for the 540i may fit on our cars? Surely someone would have done this by now if it were a possibility, but I searched and couldn't find any threads relating to the idea.
I used a Cosmos CAI on my previous 540, and it was effectively an exact replica of the Dinan unit for that car. If you could buy two of these and essentially have a replica Dinan CAI for $300...well, that would obviously be great. It really wouldn't be much different than some of the "Home Depot" DIY CAIs, but this would be premade and it was remarkable how well this particular intake(made for the E36 and E46!) fit the 540.

So, the question is: are the 540 and M5 intake tracts similar enough that an in-the-bumper CAI for the 540 could work on the M5?
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Old 26th July 2007, 16:19   #2
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EaglEye,

As I recall, Cosmos had an intake for the M5. It was essentially two 540 tubes in a mirror image.

If you do a search there was a discussion about using the Cosmos intake vs. Dinan and I think the discussion was had in the thread with the Dinan engineer back when they were participating.

This was at least one year ago so perhaps Cosmos has discontinued the M5 version.

Michael

P.S. -- sorry; should have looked before I spoke. It was not Cosmos racing but Cosmo Racing. here is the link to the M5 intake http://www.cosmoracing.com/productin...d=165&pid=1434. Quality is definitely not substantiated when compared to Dinan. Also, the discussion of the two systems was during the thread for the Q & A with the Dinan Engineer.

Last edited by mchin; 26th July 2007 at 16:26.
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Old 26th July 2007, 17:28   #3
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Indeed, I've never bought any Cosmo Racing products because the quality seems highly questionable to me. Cosmos Racing, on the other hand, makes a CAI for the E36 and E46 cars, and it just so happens it has an uncanny, almost made-to-order fit on the 540, too. I should clarify that when I say a "replica" of the Dinan CAI, I mean in general design, not materials. The Cosmos tube is made out of thick, heat resistant 3.5" ID silicone rather than carbon fiber, but beyond that the two are fundamentally very similar.

This and the possibility of using early 540 MAF housings as cheap alternatives to the Dinan parts really interests me. I have no issues with Dinan at all, I simply can't or won't pay a couple thousand dollars for basic intake parts if I can source effective alternatives elsewhere for 1/10 the price. I had a pre-Vanos '98 540, and I know first hand that the MAF housing on that car was noticeably larger(wider) than the ones on the M5. I don't know how you'd transfer the electronics given the different connector and mount styles between the two, but it's an interesting idea that I saw raised earlier on this board.
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Old 26th July 2007, 22:20   #4
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cosmos used to sell an M5 intake on ebay. i remember it stated it was mainly for the 540 so if you had an M5 you needed to purchase 2...
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Old 26th July 2007, 23:53   #5
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I have just got to put my conversion on. I have purchased the following

1x 540i Sport front bumper Grill which has holes all the way across
2x 540i Sport front brake ducts in black plastic which clip into the grill
1x 540i Sport front spoiler tip for front grill which you can buy primmed or painted
You can then cut the whole in you front arches to allow air to flow into the discs or you could buy the 540i ones which have the cut outs in them.

I am also looking at re moulding the front fog light surrounds to take air in from them to feed the 2 front air boxes. I know hamann do front fog light surround like this which you could use.

Tristan
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Old 27th July 2007, 02:32   #6
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EaglEye -- I am with you on this. I am waiting until I can find a used set of MAF's or purchase new from Dinan and then save some money by purchasing the intake from Cosmo. I hate to be cheap with such a high performance car but the way I justify the purchase is that if the performance gain is the same then I don't mind giving up the carbon fiber.

BMW MPOWER -- you can modify your own fog light surround to allow air into the cavity behind the bumper and in fron of the wheel well. I believe Philly M5 did this mod and has a post on it. the fog light surrounds come off easily and then you can cut out the area next to the fog light so that air can enter the space. I did this and then just removed the snorkel from the air box. now the air travels past the fog light into the cavity behid the bumper and up into the air box. there is no ram air effect like the AA set up but at least I have some increased flow by removing the snorkel and allowing the air box to be open without having the air come from inside the engine compartment.

good luck

michael
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Old 27th July 2007, 03:45   #7
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Quote:
Originally Posted by BMW MPOWER View Post
I have just got to put my conversion on. I have purchased the following

1x 540i Sport front bumper Grill which has holes all the way across
2x 540i Sport front brake ducts in black plastic which clip into the grill
1x 540i Sport front spoiler tip for front grill which you can buy primmed or painted
You can then cut the whole in you front arches to allow air to flow into the discs or you could buy the 540i ones which have the cut outs in them.

I am also looking at re moulding the front fog light surrounds to take air in from them to feed the 2 front air boxes. I know hamann do front fog light surround like this which you could use.

Tristan
You can use the e46 m3 foglight trim, they will give you a nice opening for the air to go through
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Old 27th July 2007, 10:39   #8
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Quote:
Originally Posted by mchin View Post
EaglEye -- I am with you on this. I am waiting until I can find a used set of MAF's or purchase new from Dinan and then save some money by purchasing the intake from Cosmo. I hate to be cheap with such a high performance car but the way I justify the purchase is that if the performance gain is the same then I don't mind giving up the carbon fiber.

BMW MPOWER -- you can modify your own fog light surround to allow air into the cavity behind the bumper and in fron of the wheel well. I believe Philly M5 did this mod and has a post on it. the fog light surrounds come off easily and then you can cut out the area next to the fog light so that air can enter the space. I did this and then just removed the snorkel from the air box. now the air travels past the fog light into the cavity behid the bumper and up into the air box. there is no ram air effect like the AA set up but at least I have some increased flow by removing the snorkel and allowing the air box to be open without having the air come from inside the engine compartment.

good luck

michael
, interesting -I've thought about this -BUT - wonder, how is it at higher speeds (120-160mph / 200-270kph)? ...I am wondering about the pressure buildup & water(rain) in there...?

thanks

Last edited by MarkQC; 27th July 2007 at 10:40.
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Old 27th July 2007, 15:57   #9
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MarkQC -- pressure build up is a good question. the area behind the bumper is not completely sealed so air can make its way around the small gaps if the pressure became too great. also, there is only a relatively thin O ring that is around the opening to the air box. if the pressure became so great it could easily slip around the O ring. Again, my solution is really not high tech and it is not as well made as other systems. I am sure I get some heat soak. I had considered making an opening in the wheel well directly opposite the fog light opening so that air could theorectically pass directkly through the cavity.

In terms of water, thankfully I have been able to avoid the deep puddles but I am now more alert to the puddles b/c of what I have done. In normal driving at speed I don't think much water enters to opening. If it does is will drain out of holes in the bottom of compartment. With regard to electronics, the temp sensor is on the passenger side together with the secondary air pump. I don't think there is anything major on the driver's side besides the horn. All of these components are relatively high up and so long as I don't submerge the front end of the car I think they will be okay.

Michael
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Old 27th July 2007, 20:31   #10
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Can someone post picture of the cosmos intake?
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