Case Studies
At Pipercross we are able to undertake any project to fulfil your air filtration needs. Whilst some of our most exciting projects have involved the development of filters for Formula 1, WRC and BTCC we are also conscious of working with all levels of motorsport. If you have a need for bespoke air filtration, we would love to hear from you!
We produce a number of off-the-shelf air filter systems for vehicles using carburettors and multiple throttle bodies from the likes of Weber and Dellorto, working with manufacturers like Webcon to ensure our range fits the widest number of applications possible.
Formula 1
Formula one is the highest form of motorsport and the hardest design challenge for an air filter system.
A good F1 filter must have the following properties:
- High air flow rate
- Low-pressure drop
- Good efficiency
- Good dirt retention
- Lightweight
- High strength
- Fire resistance
In 2002 Pipercross were commissioned by a Formula one engine builder to help with issues concerning their current filter system with issues such as:
- Metal parts fracturing and being ingested by the engine, this was caused by high resonant frequencies between two layers of mesh
- Poor sealing properties of the outer rim
- Degradation of filtration material due to increased spit back caused by the introduction of traction control. This also led to a risk in fires as the filtration material caught fire.
We overcame these design challenges by implementing the following procedures:
- Pipercross would use an all-composite filter support cage, (new and unheard of in the air filtration industry) overcoming any problems with metal parts resonating and failing. This also gave a sizeable weight saving.
- Pipercross developed new sealing materials, which are softer and more malleable then the traditional material, this material was more forgiving to tolerances between the engine and air horn.
- Pipercross in conjunction with foam manufacturers designed a new type of fire-resistant foam, coupled with a new type of retention fluid made the foam resistant to spit back and passed our own blow torch test.
The result? An overwhelming success with:
- 75% reduction in weight compared to a traditional F1 foam airfilter
- 50% reduction in weight compared to a cotton gauze F1 airfilter
- Minimised pressure drop to not restrict 800+ bhp
- High reliability
- High efficiency due to the depth of the foam and type of retention fluid
World Rally Championship
Rallying is one of the greatest test an air filter system can have. Mud, dust, water, sand, gravel and snow are all very common contaminants found in stages around the world.
We have been a leading manufacturer of World Rally Car filters for many years and work very closely with M-sport (contructors of the Ford Focus WRC). Together we have a developed a filtration system that is free flowing enough not to restrict 300BHP and highly efficient.
3 stage filtration system
Layer 1 (Green): This is a pre filter layer which traps all large size debris such as gravel, leaves, grass and rubber. This layer also has the largest amount of retention oil so even smaller particles are trapped against the cell walls. This relieves pressure from the finer layers, allowing air to pass freely through to the denser layers . - Layer 2 (Red): This would normally be the finest layer in most automotive filters, this layer traps mud, dust and sand.
- Layer 3 (White): This is the finest layer in the system and is used as a safety barrier. Because of the harsh conditions these filters are run in this layer is essential to catch the finest of particles. A secondary effect of this layer is water atomisation of whereby it allows the engine to injest a fine mist instead of large droplets.
With this type of filtration media our filter system can trap over 4 times its own weight before it is clogged in any way!
Touring Cars
WTCC
Pipercross are air filter suppliers to Ray Mallock Limited who are responsible for the Chevrolet World Touring Car, seeing in a record-breaking seven wins for the team with the Lacetti. Pipercross were also the filter of choice for the 265bhp Nissan Micra R concept
which was capable of reaching speeds of 150mph.
BTCC
Pipercross were contacted by West Surrey Racing (WSR), who were running the MG BTCC touring car. At the time of contacting us they did not have any problems with their current air filter system, in terms of performance and reliability. The problems WSR were facing were due to the service and prices of their existing foam air filter supplier.
We were asked produce and quote on a prototype filter and to our surprise we were 75% cheaper than the supplier they were already using.
During the time WSR and Pipercross have been working together, any purchasing and technical issues have been resolved quickly and efficiently to ensure the customer was happy and any issues did not effect their testing and racing schedules.
WSR have had phenomenal success within the BTCC and ETCC championships.
HKTC
Pipercross is the filter of choice for the Hong Kong Touring Car team China Dragon Racing, who successfully run Honda Accords, Civics, Integras and now the Peugeot 307 in the Hong Kong Touring car championship. We were asked to manufacture a specialist panel filter to their specification, which could offer maximum air flow and efficiency that enabled them to complete a race even with a trip into the gravel trap. China Dragon Racing's results have been exceptional as class winners in 2001 and 2003 with a runner up place in the 2002 championship.
