Custom turbo/heat shield

[Blitzeclips]

Hey guys, I've been having a problem with the heat from my turbo, manifold, and exhaust housing. Seems like everytime I look at my hood in the sunlight the paint gets foggier and foggier from the heat. So, I went to a local sheet metal shop around here and bought a 3 ft. x 8 ft. sheet of 26 gauge galvanized steel. Cost me $12.36. Other then my center console layout I don't have any other projects going on so I figured I'd see what I can do with it in my free time. I'm not done by any means. I still need to do some welding and grinding, then some polishing and installation (final). I've already located my mounting points but I need to weld the L brackets on the actual metal to have them on the actual shield. Anyways, here it is so far..

First I used a sheet of paper for a template to base the shapes off of. I didn't want the shield any closer then 1" from everything. I plan on ceramic coating then insulation wrap in the future. So I left some room for those in the future.. Here's the rough idea..
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0070.jpg

Then I laid the template over the corner of the sheet metal and measured the lengths, widths, etc. of the shape. (just incase I mess up too, I would something to reference from in the future, if I needed to make another) Notice I used the corner of the sheet. I needed the most accurate right angle for a clean look when installed. Can't beat the factory form..
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0072.jpg

Here's a pic w/ the paper template laid over the metal outline.. Notice I left about 1/2 of extra room at the top incase of bending, mess ups, or any damage from fitment.. I want the metal as 'bend/crease free' as possible. So it doesn't look retarded when I'm done..
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0071.jpg

Now here's a step that can ruin the whole thing cosmetically if you do it incorrectly. I don't have acess to a sheet trimmer, so I used some snips we use for the bikes. There's a specific way to cut this metal. If you look here closely, you'll see the wrinkles and imperfections across the cut. This is from snipping through the entire length of the blades on the end of your tool. You need to use 1/2 cuts, then continue the entire length without doing a full snip of the 'scissors'.. Sounds confusing but hopefully you kno what I meen.
Here's where alot of people make mistakes, notice in the glare..
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0073.jpg
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0074.jpg

Alright so I cut and snipped everywhere outlined in the template. Once I had the actual flat piece of sheet metal, I needed to make the curves/bends for the manifold. To do this, I used a PVC pipe, to which was AS CLOSE AS POSSIBLE to the diameter of my manifold ports. I figured 3" was suffice, so I piched the end pieces of the metal with the PVC, then rolled then along the area of bending. Took me a couple strides. You may find imperfections in the bends, but if you hold the metal flush with the pipe, you can use a rubber hammer to knock it in the general shape. I didn't take any pics of this process, because my hands were tied, so I'm sorry if you get confused there.
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0075.jpg

Here's another angle. I wanted to make sure there was enough room under the shield for the manifold to somewhat breathe, and make way from the carmic coating, etc..
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0076.jpg

Now here's where I started getting more intricate I guess. I made 2 extenions, each almost 8" long, with a mild curve to them. See the little stubs bent out by the beginning of the exhaust housing? Thats where the 2 extensions mate to the shield. I'm going to spot weld them on and make sure everything fits correctly, then I'll finalize with full welding around and polishing. These extensions run down almost underneathe the housing, so the radiant heat will be shield from my radiator also.
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0077.jpg


This angle should give you a better idea of what I meen with the extensions..
http://i35.photobucket.com/albums/d162/blitzeclips/PICT0078.jpg

Like I said I'm nowhere near done but I know alot of you guys have the same heat problem. Hopefully by the end of this thread you will be able to make one with ease and for less then $15. I plan on having mine chromed or polished but IDK yet. We'll see how everything fits up and works out. So far, so good.

Still on list:
* Spot weld extensions
* weld brackets for mounting
*weld all surrounding plates for structure support
*check fitment
*polish/chrome

I'll be doing some work on it tonight and tomorrow maybe. So I'll keep you guys updated I guess..

 

[shiftdrift06]

Looks awesome!, something I been waiting for.

 

[cs82685]

Blitz that's looking pretty good. Nice write-up so far.

 

[dr1665]

Personally, I think I would just buy a cheap cooking pot big enough to fit over the turbo. Iv'e seen it done and, surprisingly, it's one of the best looking heat shields I've ever seen.

 

[diablos991]

Nice write-up.

Those couplers look like they could use some attention.

 

[TalonESIT]

Personally, I think I would just buy a cheap cooking pot big enough to fit over the turbo. Iv'e seen it done and, surprisingly, it's one of the best looking heat shields I've ever seen.

This sounds very interesting, care to guide us to any pictures?

 

[shiftdrift06]

This sounds very interesting, care to guide us to any pictures?

Was on 2gnt.com
http://www.supraforums.com/forum/showthread.php?t=326366

Thats nice an all but, I like to cover the manifold also.

 

[TalonESIT]

Was on 2gnt.com
http://www.supraforums.com/forum/showthread.php?t=326366

Thats nice an all but, I like to cover the manifold also.

OH WOW!!! I had no idea!! Thanks for the pictures, it is a damn clean install.

 

[BigRand]

i'm thinking about trying that either this weekend or the next

 

[4UH8ERS]

It absolutely amazes me how straight and smooth the cut was on that cooking pot heat shield.

 

[Blitzeclips]

Ok let's hi-jack the thread then ...

I'll give an update but if everyone wants to follow the cooking pot then I won't bother with the write-up. I can just make it myself then show you all without taking pics every 2 seconds...

Anyways, I ended up using a method of bonding metals called silver soldering. It basically brazing the two plates together using heat and a certain type of metal. It made the two sheets mate toegethet much cleaner. So when I go to do my final welding it will be a clean, strong job. Not only that but it helped well for fitment. Everything checks out pretty good...

I am at school right now so when I get home I will post some pics up.

 

[VelocitàPaola]

He has a point... if someone wants to start another thread about the pot/heatshield, feel free... but this is Blitz's thread.

 

[Blitzeclips]

Thanks Paul. Also for reference guys, for effective use of these you want to almost create an oven type isolation around the hot areas. That's why the stock heat shield bends in the downward direction so dramatically, to trap the hot air in an area away from outer/other engine components. That's the primary purpose of the shield.

That cooking pot 'heat shield' isn't going to do about anything for that car/turbo. It's a mere shield of anything. No longer involved with heat control...

 

[VelocitàPaola]

Well I don't know about that... several reputable manufacturers make heat shields identical in design to that pot. Let's stick to speaking from experience here...

 

[Blitzeclips]

Well I don't know about that... several reputable manufacturers make heat shields identical in design to that pot. Let's stick to speaking from experience here...

I'm sorry, Paul. Put it this way: It came directly from 2 buddies in the engineering field. One certified on a university level and one into their 3rd year of study..

You guys get my point...

 

[VelocitàPaola]

Hey Blitz, can you get me some rough dimensions of the manifold? I want to try to sketch something in AutoCAD for you.

i.e. how long it is, how wide it is, and how deep it is. Also, how wide the turbo flange is, and how far the turbo flange is from either side of the edge of the manifold.

 

[BigRand]

hey blitz...are you gonna do the turbine housing as well?

 

[Blitzeclips]

Sure, no problem. The dimensions for the manifold cover..
Width: 14.5"
length (from head up to turbine): 8"
The depth is based off the curves I made that mimic the manifold: runs 3" deep from top of sheet; down.
Width of flange: 4.5"
Turbo flange from edge closest to the head(under coolant tube): 8" w/out any curves


Rand, yeah I've already created the cover for it. I extended the shield with some pieces that curve arund the exhaust housing pretty good. It's about 1" from the actual housing so I left plenty of room for insulation wrap and/or ceramic coating.. It was silver soldered onto the lips I made at the beginning of the turbo flange...

I'm getting pretty frusterated bcause I took alot of pics on my digital and it's not turning on for some reason.. I'll post pics when I figure it out..

 

[VelocitàPaola]

Actually, how far is the flange from the left of right side of the manifold... or is it perfectly centered?

Also, I recommend running the oil line above the heat shield for obvious reasons.

Finally, how are you securing this thing? Find a way to bolt it down tight... I suspect it'll vibrate like crazy unless it's really tightened down.

 

[Blitzeclips]

Well, I figured out what was up with my digital:

So, I got the two plates to wrap around my housing and silver soldered them onto the original shield for my manifold. Notice how I used the backside for this, I crimped a lip for the two plates to connect in a very clean way.
If you can tell, the last pictures showed a sharp, round corner for the manifold cover. Notice on the right side, I trimmed it down and rounded that corner a bit. So it looks a bit more smooth.
http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0085.jpg

http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0086.jpg

Lined the excess shield up a little better..
http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0087.jpg

Okay, so here's the extra sheet I left for trimming later on. I wanted to extend these a bit to block heat from my radiator. They will be trimmed symetrically for an even weld and protection..
http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0089.jpg

Now I need to make sidewalls for some structure. I used paper as a template and just traced it out until it fit correctly. Took some trial and error but that's expected..
http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0092.jpg

Fits pretty good on paper, even better with metal..
http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0090.jpg
http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0093.jpg

The seams you see from the solder will be welded and grinded down for a smooth, clean, one piece look. Not only that, but there will be welding in alot of area that look unsecure...
Also, after a closer look with some buddies we are debating on changing the extended shield on the left (not right) to bend downward torwards my downpipe a little more. We think it might isolate the heat a little better. So if I change anything I'll be sure to keep you updated.

Here's a quick pic of another project I'm working on... New dash layout in fiberglass. Just the skeleton with rough layout..
http://i35.photobucket.com/albums/d162/blitzeclips/heat shield/PICT0105.jpg

I have created extra room for the oil line to protrude form the shield.

Paul, I have located 3 or 4 mounting points if needed. Vibration is a concern already, but these moutning points should prevent ANY vibration. They're ideal locations, I'll have to point it out in my next pics for you all..

BTW, here's the bigass piece of sheet metal I bought for $12. I used maybe 3'x2' AT MOST. That's roughly $3 or so for material. Sounded like a deal to me..

 

[4UH8ERS]

I like it. Do you think it would be easier to make 2 seperate heat shields 1 for the manifold and one for the exhaust housing of the turbo?

 

[VelocitàPaola]

I think it would be... I've been working on a heat shield for a little while, but I've decided to hold off until I upgrade my turbo and manifold. I plan on just getting a pre-made heatshield for the turbo and making one for the exhaust manifold.

 

[Blitzeclips]

Eh, it might. I don't think I want to do that though. I am making this VERY easy to remove if need be. I like to check for oil leaks and stuff like that around the turbo. So I wanted to keep it all in one piece, also to make it less prone to vibration. I wouldn't want some bolts popping up out of nowhere on the shield, I prefer the cleaner look...

What are you upgrading to, Paul? 20g?

 

[VelocitàPaola]

GT35R or GT40R.

 

[VelocitàPaola]

Ok...

Don't take this the wrong way, I'm not trying to undermine your efforts here, but here is how I would make that heat shield. I would do exactly what I said in my previous post, put this over the manifold and buy a separate one for the turbine housing. It's just two parts... nothing too difficult when it comes time to take it off.

It's got six anchor points, so it shouldn't rattle or shake around. It fully envelopes the manifold, except for the bottom. The measurements I have are extrapolations based on what you gave me, and what I found from a scaled picture. If I were to come across more exacting measurements, it wouldn't be too difficult to modify so this thing sits perfectly.

Plus, if you were to get it cut by a laser cutter, all you would have to do is bend it, and insert two pop rivets. Nothing to it! Two to four spot welds would be nice, but not necessary.

I mocked it up in a scale, paper version. It's surprisingly stable (as in, not flimsy) due to the upper lip.