Joel's CAI System w/ Oil Catcher (3D Printed)

Hello fellow 3rd gen'ers. I wanted to share my 3D printed Cold Air Intake System I CAD'ed up in Solidworks from scratch. All I ask in return is that it is called "Joel's CAI."

I have used it for over 6 months now with about 15k+ miles on it. Along with that it's also been through 120+ degree summer heats and the recent heavy rain storms we been having here in LA without a single check engine light coming on or any other issues.

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I printed this intake system using ABS filament and treated it with acetone vapors to help smooth en out inner walls for a better air flow and to help with the part's structural integrity.

This isn't a perfect CAI in respect to fitment and performance. I didn't use any fancy 3D measuring system (which I tired but wasn't successful) to create this CAD model so you will need to do a little cutting and sanding to get it installed. I also didn't perform any fluid dynamics analysis to the model mainly cause I don't have the software but I am assuming this does increase my Prius' performance and I have the backing of my butt dyno to prove it.

Installing this intake system you'll need to mod a few thing in your engine bay like undo the MAF sensor wiring to reach its new location and cut the plastic "air blocker" part that is between the radiator and the car's frame.

For the elbows after the throttle body and MAF sensor I simply bought from amazon (High Performance 90 Degree Elbow Coupler Silicone Hose (2.75" / 70MM). You can 3D print those 90 deg elbows using flexible filament but I personally haven't had much experience with flexible filament.

The intake filter is a K&N RU-2820 and I simply attached it to my radar's vertical bracket using zipties. Pri without the advance technology package wont have this radar bracket with mean you could potentially put a longer intake filter and you'll need to find some other way to support your filter.

The oil catcher has Cable Tie Mounts (from Home Depot) bonded underneath and zip tied to the engine. On the top of the oil catcher I hot glued on a breather filter after removing its rubber coupler.

There's a lot of detail I can't remember at the moment about this project. But I'm willing to pop my hood for anyone who want to see it in person. I could use the free coffee .

Happy printing!

 

STL files can be found here on Thingiverse

Prius Cold Air Intake w/ Oil Catcher - Thingiverse