PiCA Duct - Cool Air intake for Kia Picanto (JA 2020)

Intro

Introducing the PiCA Duct, designed to improve air flow into the 2020 facelifted JA Picato's intake system. 

Standard Picanto routing takes airflow from behind the bumper, and is positioned above the air-con system. As a result it suffers from heat soak, and sucking in hot air. The PiCA Duct relocates the intake entry to the front bumper opening, providing air directly from the incoming airflow.

This multipart model bolts directly into the car, requiring no modifications to the vehicle. Also provide a trim strip to add a splash of extra colour to match your Picanto.

Note: Has been proved to fit the 2020 JA facelifted models fitted with the GT style front bumper. This covers the three engines (G1.0 MPI, G1.2 MPI, G1.0 T-GDI). Has not been tested on older/newer JA's, or the basic specification front bumper.

Parts & Print Settings

There are four components to the duct. The two main body pieces, trim strip and badge. Each part will fit within the standard Mk3/Mk4 build volume (X:250 Y:210 Z:210).

Main duct areas have been designed for minimal support structure.

Duct Top/Bottom Recommendations;

• Material - ASA or other higher temp resistant material
• Nozzle - 0.8mm
• Layers and Perimeters 
  • 0.28mm Layer Height
  • 5 top layers
  • 4 bottom layers
  • 0.96mm line width
  • 4 perimeters
  • Arachne
  • minimum 0.2mm elephants foot compensation
• Speeds - Perimeters @ 45mm/s, External @ 25mm/s
• Supports
  • Organic
  • ‘Support On Build plate only’ On
  • ‘Don’t Support Bridges' On
• Infill
  • 20% Rectilinear
  • Bridging angle - 135° (check part orientation image), helps for shorter bridges over internal features.

Trim ring

Default PLA, 0.4mm settings will be fine. No supports required.

Badge

Badge is four layers. For best impact, make a multi-colour print (recommend White/Red) switching colour at the third layer. 

Assembly

Once printed, simply glue the two duct pieces together using suitable glue. Some slight deburring around the top part may be required for best fit, depending on first layer squish. 

Trim ring mounts around lower duct opening, simply glue in place.

Badge has embossed area to be stuck to.

Installation

Remove front bumper from car as shown in this video. You'll need to unplug the front Fog Lights before being able to remove the bumper. 

Remove the standard duct via the two 10mm bolts, and two press clips into the intake (behind the front upper beam). 

Install duct through the upper beam, and reconnect the intake pipe and press clips. Bolt duct to front beam with single 10mm bolt (won't be able to access second screw hole). 

Replace front bumper in reverse of video, and your finished!