Another Cai/heatsheild

[one.etik]

Hi all, Just completed my CAI and heat shield on the weekend and figured I'd post up some pics. Unfortunatly I didn't think of this when I was actually making and installing it, but its not rocket science so you'll get the idea

Materials Used

Petrol Funnel (bought from local servo) $5

100mm AirCon Duct (breeze-air shop, scrap from old install) $?

2 X "600mm x 300mm x 3mm 602 grade aluminium sheets" (Local aluminium wholesaler) $30

10mm 90 degree aluminium edging $3

Rubber Edging

Zip Ties

Duct Tape

bit of 16mm conduit

pop rivets

and a some free time

Method

Started off by cutting the funnel to suit the size of the air duct, then used duct tape to secure it to the funnel. Due to my Front mount only using one of the stock intercooler holes I was able to utilize the other one. I zip tied the air duct to the back intercooler hole and used a bit of conduit around the edge to hold it in properly. I mounted the funnel to the fmic piping in the bottom right cut out of my kit.

Next was the Heat shield, After reading through many of the cai threads, figured I'd go with the cardboard templates to get the shape. After a bit of stuffing around trying to get it to fit, I traced the template on to the aluminium and started cutting, probably could have gone for a thinner alluminium cos it took a while to cut and file it to size. Once that was done, pop riveted the 90degree angle stuff to the edge to hold the final product together. Added a bit of rubber edging and easy as that.

Hope this may help anyone looking to go down this road.

[PsYLoR]

You can add a bit of insulation to the inside of the box, stops a whole lot more heat from passing straight through the metal.

[Hijacker...]

Like your mumerfied cooler pipes?

Edited July 8, 2009 by Hijacker...

[one.etik]

You can add a bit of insulation to the inside of the box, stops a whole lot more heat from passing straight through the metal.

Good idea, didn't think of that