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Company Representative for Evolve Automotive
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Evolve Engineering Venturi Air Intake (VAi) - E60 E61 M5 / E63 E64 M6


…………… The Most Comprehensively Designed and Engineered S85 Intake System …... in the World



M5-Intake-Engine by evolveautomotive, on Flickr


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Introduction

After 8 months of development and testing we are proud to now officially launch the Evolve Venturi Intake System.

Development started from a desire to complete our tuning package which already consisted of our well known Evolve ECU Remap, Evolve Tubular Headers and Evolve Exhaust.

We wanted to design a system which gave a positive impact for the whole driving experience. By taking advantage of aerodynamic principles and using computational fluid dynamics to optimise the airflow, we have engineered an intake system which delivers on all fronts - sharpened throttle response, more torque, improving driveability and of course, increased power.

More power was required but not just at the peak rpm region which is used maybe 5% of the time. Too often we have tried and tested intake kits which seldom increase power and even if they do, it is at the detriment of the low to mid-range torque and throttle response.



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Hardware

exploded-front-E60-Intake by evolveautomotive, on Flickr

The hardware consists of a combination of 79 individual high quality components including:

- Pre Preg Carbon Fibre Housings with Individually Serial Numbered Plaques
- CNC Hard Anodised Aluminium MAF housings
- CNC Machined Engineering Plastic MAF bosses
- CNC Machined Engineering Plastic Secondary Air Flow Breather Adapter
- Aluminium Hard Anodised Spun Cowls
- Laser Cut 3mm Brackets
- Laser Cut 2mm Neoprene lined OEM hose clamps
- Aluminium Powder Coated Upper Air Scoops
- Aluminium Powder Coated Lower Scoops
- Hose Clamps (BMW OEM Norma)
- High Quality Silicone Hoses
- OEM Quality Anti Vibration Mounts
- Stainless Steel M5 Cap Head Machine Screws and Washers
- High Flow Air Filters and Breather Filter
- Misc Brackets and Nuts


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Initial Impressions

Irrespective of our individual thoughts and testing, the most important aspect is how our customers feel after installing the intake kit and how their driving experience has changed.

Here are some quotes from the first customers from this forum:

“I don’t think I need to say much more on the sound. It’s Intoxicating”
“The difference in low end torque is really impressive for a set of intakes”
“The difference in throttle response and agility is huge. The performance is great, they look awesome and the noise is really special”
“When pulling hard the intakes open up and sound like a V10/CSL mule”
“There is definitely an increase in throttle response, which I feel our cars really lack”
“Definitely pulls harder in the lower RPM’s. For the higher RPM’s, I have noticed more power compared to my Dinan setup”
“But when I put my foot down it’s like I’ve opened the valve to a sports exhaust”


The above quotes mirror our initial impressions which still remain after covering thousands of miles in our E60 M5 which gave us a great sense of satisfaction.



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Engine Power


There were two main considerations to balance when designing the Evolve VAi kit:


Aerodynamic Efficiency

For aerodynamic advantages an open system was adopted but not in the "normal" aftermarket method. To ensure a less restrictive design alongside maintaining high air-speeds the Venturi Effect was implemented. This can be clearly seen from the shape of the carbon fibre housing and the location and shape of the air filter. The entire carbon fibre housing is a Venturi where the airflow increases in velocity as the cross sectional area reduces from the mouth (filter opening) to the outlet into the MAF tube. By inverting the cone and placing it on the mouth of the intake, the carbon fibre housing dictates the shape of the airflow. As this is essentially a large funnel - the airflow remains laminar and therefore minimises the drag of the system therefore reducing load on the engine.

CFD-airflow by evolveautomotive, on Flickr



Inlet Air Temperature

The OEM intake assembly, being a sealed system is very efficient at keeping IATs close to ambient when the engine is under load – wide open throttle driving conditions.
However, data logging clearly shows that under idle and slow speed driving conditions IATs will always be high for a sealed or open system. This is due to heat soaking of the intake assembly from engine heat as well as the recirculation of hot air from the breather system.
To ensure the Evolve VAi open system came as close as possible to the OEM system, two pairs of air scoops and one pair of radiator deflector shields were engineered.
On road data logging clearly shows IAT's to be very close to ambient temperatures especially under full load and while the vehicle is in motion.




Conclusion of IAT and Air Flow

Increased Engine Performance

This is clearly apparent through the increase in power under both partial and full load engine conditions especially low-mid (1000-5000) RPM driving where the S85 suffers from inconsistent and weak power delivery
Dyno testing, where airflow is equivalent to road conditions confirms the above with increases of 10-15 horsepower (see figure 1.1)


Improved Drivability

A result of the Venturi effect is the improvement in air speed especially under transient throttle openings. The direct effect is improved throttle response which makes the engine feel more alive.


Enhanced Overall Driving Experience

The enhancement in driving experience comes not just from the improved throttle response and power but also from the by product of such a design – SOUND.
The carbon fibre housing coupled with the open design gives rise to a resonating and deep induction roar similar to that of a racing V10 engine. However, unlike a simple open cone filter, the Evolve VAi’s produce a refined pulsing symphony under varying engine speeds and engine loads both inside and especially outside the car.



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Dyno Testing Results


M6Dyno by evolveautomotive, on Flickr


Dyno testing was carried out on our in house Dyno Dynamics DS450 Dynamometer. For the purpose of accurate testing all tests were matched based on:

- Inlet Air Temperatures through in built IAT sensor in MAF via OBDII
- Ignition Timing Matched (Ignition timing can vastly change from one run to the next)
- Engine Temperature (Coolant and Oil)
- Exhaust Gas Temperature
- Two consistent runs recorded for each of the below tests

Testing Proceedure:

- Test 1 : Stock car, stock tune, stock intake system and euro filters (equivalent to charcoal delete)
- Test 2 : As above plus Evolve Upper Intake Scoops
- Test 3 : Stock car, stock tune, Full Evolve Engineering VAi Kit


Crank Horse Power Dyno Dynamics Calculated (Shootout Mode 8)

E60 M5 Stock Cat Test 1 Carbon Intake Flywheel by evolveautomotive, on Flickr


Wheel Horse Power Dyno Dynamics (Shootout Mode 8)

E60 M5 Stock Car Test 1 Evolve Carbon Intake Eventuri Wheel Power by evolveautomotive, on Flickr


Dyno Testing Conclusion

Full throttle dyno testing shows that power and torque upto 6000rpm is increased consistently through the rpm range by approximately 5-7hp
Between 6000-8250 rpm the power increase is larger at a consistent 10-14hp

These results are mirrored by the on-road driving experience



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Images

cataloguepage by evolveautomotive, on Flickr

e60 m5 m6 intake exploded side by evolveautomotive, on Flickr

evolve e60 m5 m6 front intake by evolveautomotive, on Flickr

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Videos


(We would like to thank Randy and Gian for supplying some of the above videos)


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Pricing / Availability / Instructions / Contact

Pricing

- 900 GBP (£750 + 20% VAT) UK Mainland and EU Countries
- 750 GBP (non EU)
- 1250 US Dollars

Shipping

- 20 GBP within UK
- 85 US Dollars (USA)

(for rest of the world, please contact us for a quote or contact your local dealer)


Lead Times

Due to demand currently 28 working days from placing order and payment


Instructions Download

Click Here to Download Instruction Manual


Contact

For more information or to purchase please contact us on:

E: [email protected]
T: +44 (0) 1582 584 000


We would like to make a special thanks to the M5board members for their continued support and enthusiasm.



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Nice....pricey but nice. It will be on my Christmas list.
 
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