3D Air Systems
"Big Mouth" Air System
"Big Mouth" Air System
** The Big Mouth system uses 1.5" hose outlets, and includes a short run of 1.5" hose that goes into our step-down adapter to use your standard 1.25" hose out to your helmet. For the industry standard 1.25" outlets, click HERE. All other features are the same. This option offers the most air possible, but the initial hoses leaving the unit are bigger and take up more space in the bending radius. The difference is minimal, but does help promote a cleaner path for the air and reduces the chances of the fan spinning too fast due to backpressure.
* Each unit is made to order and our current lead time is roughly 2 weeks from order date.
After hundreds of hours of on-track testing from some of the best racers in the world, the new standard in helmet air systems is here! Our talented design team of racers and recreational off-road enthusiasts has blended with the input from professionals and trail riders from all over the country to create the new reference point in fresh air pumper systems.
If we make this unit to easily withstand season after season of brutal, professional off-road racing, then it will be able to handle any application you can find with ease. It doesn't matter if you're in a fully built Ultra4 4400 rig ripping around in the moon dust at King of the Hammers, or in a side by side with your family ripping around the dunes, you'll appreciate knowing your air system will be strong, clean and won't fail. Our goal is to make the best air system available, with no compromises.
The 3D Air Systems helmet pumper utilizes a dual stacked fan to pull in a rush of dusty air into the custom aFe Power Dry S filter, where it passes through 3 layers of premium, deep pleated media. Another feature of our exclusive filter is the addition of an inverted cone on the top, which increases the surface area of the filter media, allowing for more flow and dust capacity. An integrated channel in the filter flange interacts with a lip in the housing to lock the filter in, as a backup to the stainless steel worm clamp. The fresh air is then pushed through the gasket sealed, 3D printed housing and across internal twisted airfoil vanes to guide it into the hose outlets as efficiently as possible. Creating positive pressure in your helmet is important to keep you cool and to make sure the dirty air has a harder time getting past your helmet skirt.
*The use of a helmet skirt is mandatory for best results. Without it, dirty air can easily find it's way into your helmet.
Proper power delivery is an important part of our system, so we choose to use quality materials on the wire harnesses, as it's one of the most critical pieces to keep your system running in the harsh electrical environment found in many off-road vehicles. Our harnesses utilize 14 gauge TXL wire, genuine TE Deutsch connectors (not knockoffs) with quad-crimped solid contacts, braided split loom and double wall, adhesive lined heat shrink. The harnesses are temperature resistant from -40F to 260F and the braided loom offers excellent abrasion resistance. On top of making sure the system is getting the required power, the fans have a soft startup, building up speed slowly so it won't produce an electrical spike in your system.
With so many different applications out there, we offer a variety of mounts and options to fit your needs. Our mounts cover just about every situation with a flat surface mount or roll bar mounts in vertical and horizontal orientations.
By using additive manufacturing (3D printing), we're not tied to expensive molds, so improvements can be made when necessary. Many companies resist improvements or changes because they're trying to get the most revenue out of a mold as they can, which can stifle innovation. For those of you who question the durability of 3D printing, we have not had a failure with breakage or splitting of the housing in over 2+ years of hard testing. Due to the nature of 3D printing, there can be slight imperfections in the unit, like layer lines or seams where the walls come together. We do our best to make sure that each unit looks as good as possible and nothing will get sent out that we wouldn't want on our own vehicles. With the glass fiber imbedded material we use, most of the layer lines are hard to see unless you're up close and looking for them, giving a clean frosted look.
Options :
- Mounts : fixed for bolting to flat surfaces, vertical roll bar or horizontal roll bar in 1.5", 1.75", 1.87", 2" & 2.5"
- Filters : standard OR with a 1/4-20 threaded stud. Choose the standard, unless you plan to use a filter cover with the 1/4" hole
- Colors : Due to color variations from batch to batch, and what you see on a screen, we can't guarantee an exact color match. We use the correct hex codes for the color in the option set, so that is as close of a representation as we can offer online.
All mounting hardware is 304 stainless steel, with a black oxide coating on the bolts and washers for good looks and protection from the elements. The mounting points points use embedded nylock nuts to prevent the mounting screws from loosening under strong vibrations over time.
The housing, mounts and outlets are printed from PolyEthylene Terephthalate Glycol with glass fiber (PETG-GF), which is good up to 180F and offers a nice clean aesthetic. If you need higher heat resistance, we can do that for special projects. Having stated that, we do NOT advise pushing 180F air into your helmet for obvious reasons and recommend this situation for parts cooling. If you need a high temp unit, reach out to use through email and we'll get you squared away.
Dimensions
Body of air unit : 4"x4"
Diameter of air filter : 5.3"
Height of unit : 9"
Weight of unit : 2.5 pounds
Max power draw : 9 amps (110 watts)
Protections : over voltage, reverse polarity & locked fan rotor
DC Voltage : 10.6v-13.8v. If the voltage is higher, the fan will spin faster than the blades are designed for and induce more noise
Operating temperatures : -5F to 160F
Operating temperature of wire harness : -40F to 260F
In the interest of transparancy, now for the downsides. Our full sized units are slightly bigger than the other similar options on the market, by about 1" all around, and are also slightly louder when spinning at full speed. The noise shouldn't come as a surprise, as we're moving a lot more air, and the natural byproduct is noise. However, if our unit is turned down to match the output of others, ours is actually quieter because it's more efficient. Price is also another downside to some, but we can't sacrifice quality in search of more sales. As Benjamin Franklin famously said, "the bitterness of poor quality remains long after the sweetness of low price is forgotten." We also choose not to "waste" costs on things like fancy packaging because it doesn't add any value to the actual unit when you're out in the dirt. After dropping tens of thousands of dollars on your vehicle, spending a bit more to make sure you're comfortable while wheeling is "cheap" insurance.
The air systems are designed, tested, printed and assembled in Colorado. Our wire harnesses are also assembled in Colorado. The filters are exclusively made for us by aFe Power and the outer filter socks are made by Filter Wears, both in California. We source the fans from the Philippines for a small premium in lieu of China. Sourcing our materials from reliable, American based companies is an important aspect for our business. We want to support American companies and avoid any delays due to global instability. While we aim to offer the best air systems on the market, we understand that our approach might price out some potential customers. However, we refuse to skimp on quality materials, and feel the pricing is in line with what you get and our margins are fair.
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