Hellcat/Redeye/Demon Air Intake Designs

Goals:

• greater than OEM filter surface area (increased area to flow clean air; increased dust capacity)
• close to ambient air; air sourced from outside the engine bay
• less restrictive intake tube; least restrictive design will yield the largest performance gains on supercharged/modified/heavily modified engines
• low thermal conductivity material (rubber, carbon fiber, plastic composite tube)

*measured in inches

Real World Example: 2015 Stock Hellcat vs Legmaker Intake
144.56 mph vs. 147.54 mph in the 1/2 mile (+2.97 mph)

aFe Stage 2 (2015+ Hellcat)
Filter: 5-layer Pro5R - 7.13 flange (circle), 7 top (circle), 8.75 base (rounded-square), 6.75 height, 4b x 2.5t x 2h inverse velocity stack
Tube to TBody: Composite Plastic, 39.9 to 10.29 sq-in
Filter Surface Area: 176.91 sq-in measured

aFe Track Series Carbon Fiber (2018 Demon, 2019+)
Filter: 5-layer Pro5R - 7.5x5.5 flange (oval), 5.75x3.75 top (rounded-square), 9x7 base (rounded-square), 10 height
Tube to TBody: Composite Plastic, 32.39 to 10.29 sq-in
Filter Surface Area: ~227 sq-in (airbox flow restricted to ~151 sq-in; air box top to hood, headlight tunnel, and triangular bottom; 2019+ hood airflow restricted with rain shield installed)

OEM 2018 Demon and 2019+ (1130 CFM Redeye, 1134 CFM 2020+ Super Stock, 1150 CFM 2018 Demon)
Filter: multi-layer - 6.5x5.25 flange (oval), 5.5x4 top (rounded-square), 7.25x6 base (rounded-square) 8.25 height (est)
Tube to TBody: Rubber, 30.66 to 10.29 sq-in
Filter Surface Area: 185.71 measured filter area (airbox flow restricted to ~151 sq-in; air box top to hood, headlight tunnel, and triangular bottom)

K&N 63-1577 Redeye/Demon (2018+)
Filter: 6-layer - 6 flange (circle), 5 top (circle), 7.5 base, 10 height
Tube to TBody: Composite Plastic, 28.27 to 10.29 sq-in
Filter Surface Area: ~196.25 sq-in

Corsa 44004 Hellcat/Redeye/Demon (2017+)
Filter: 5-layer - 6 flange (circle), 4.75 top (circle), 7.5 base (circle), 8 height, 2.5b x 1.5t x 2.5h inverse velocity stack
Tube to TBody: Carbon Fiber, 28.27 to 10.29 sq-in
Filter Surface Area: ~172 sq-in (2019+ hood airflow restricted with carbon fiber rain shield installed)

2019+ Hellcat OEM (1048 CFM Hellcat)
Filter: multi-layer - 6.5x5.25 flange (oval), 5.5x4 top (rounded-square), 7.25x6 base (rounded-square) 7 height (est)
Tube to TBody: Rubber, 26.79 to 10.29 sq-in
Filter Surface Area: 159.85 measured filter area (~151 enclosed air box; lower triangle, front headlamp, upper hood)

Legmaker Redeye/Demon (2018+)
Filter: 8-layer S&B - 6 flange (circle), 5.25 top (circle), 7.5 base (circle), 7 height, 3.5b x 1.5t x 2.5h inverse velocity stack
Tube to TBody: Carbon Fiber, 28.27 to 10.29 sq-in (shorter tube than Hellcat version)
Filter Surface Area: 144.16 measured

Legmaker Hellcat (2015+)
Filter: 8-layer S&B - 6 flange (circle), 5.25 top (circle), 7.5 base (circle), 7 height, 3.5b x 1.5t x 2.5h inverse velocity stack
Tube to TBody: Carbon Fiber, 28.27 to 10.29 sq-in
Filter Surface Area: 144.16 measured

K&N 69-2550TTK Hellcat (2015+)
Filter: 6-layer K&N - 6 flange (circle), 5 top (circle), 7.5 base (circle), 7.5 height
Tube to TBody: Composite Plastic, 28.26 to 10.29 sq-in
Filter Surface Area: ~147 sq-in

JLT Hellcat (2015+)
Filter: 8-layer S&B - 4 flange (circle), 5.5 top (circle), 7 base (circle), 7 height
Tube to TBody: Composite Plastic, 15.89 to 10.29 sq-in
Filter Surface Area: ~137 sq-in

BWoody Hellcat (2015+)
Filter: 6-layer K&N - 5 flange (circle), 5 top (circle), 6.5 base (circle), 6.5 height
Tube to TBody: Metal, 19.63 to 10.29 sq-in
Filter Surface Area: ~117 sq-in

OEM Hellcat 2015-2018 (1048 CFM Hellcat)
Filter: Paper Gauze
Tube to TBody: Rubber/Plastic Composite 12.56 to 10.29 sq-in
Filter Surface Area: ~115 sq-in: airbox restricted to ~36 sq-in headlight tunnel and triangular bottom
CFM: 610 g/s converts to 1055 CFM (max airflow) @ .52 in KPa (2.0 in H2O)

aFe GT Momentum Hellcat (2015+)
Filter: 5-layer Pro5R - 6.75x4.75 flange (oval), 7.25x5 top (rounded-square), 8.25x6.25 base (rounded-square), 8.5 height, 4b x 2.5t x 2h inverse velocity stack
Tube to TBody: Composite Plastic, 25.17 to 10.29 sq-in
Filter Surface Area: ~218 sq-in: airbox restricted to ~36 sq-in headlight tunnel and triangular bottom

Stock Demon 170 Engine
44,800 L/min (1582 CFM)

Stock Redeye/Demon Engine/Super Stock
32,500 L/min (1147 CFM)

Stock Hellcat Engine
30,000 L/min (1059 CFM)

Stock 392 Engine
Filter: 731 CFM (max airflow) @ 2.0 in H2O

Headlight Tunnel and Triangular Bottom Opening
Surface Area: ~36 sq-in (this was the main airflow restriction until 2018 Demon and 2019+ OEM passed airflow through the hood)

Intake Tube Materials
Materials to consider based on thermal conductivity (low) and specific heat properties (high). A material that has low thermal conductivity reduces the heat transfer by conduction (material to material contact). A substance with a high specific heat capacity can absorb a large quantity of heat before it will rise in temperature (water has a high specific heat). A substance with a low specific heat requires relatively little heat to raise its temperature (copper has a low specific heat).

Rubber (0.13 @ 25 deg C - lowest thermal conductivity, 0.48 - highest specific heat)
Plastic (0.3 @ 25 deg C - lower thermal conductivity, 0.40 - higher specific heat)
Carbon Fiber (1.7 @ 25 deg C - low thermal conductivity, 0.17 - low specific heat)
Stainless Steel (16 @ 25 deg C - moderate thermal conductivity, 0.12 - lowest specific heat)
Aluminum (250 @ 25 deg C - highest thermal conductivity, 0.22 - low specific heat)

2015-2018 Challenger Lower Air Box


2019+ Challenger Air Box / 2021+ Charger Redeye Air Box


2015-2018 Challenger/ 2015+ Charger Hood Vent


2018 Demon "Air Grabber" Underhood


Challenger Redeye/Hellcat 2019+/Super Stock Underhood


2021 Charger Redeye Underhood


2015-2016 Hellcats MAF sensor

2017+ use IAT sensor