2G Finished cold air intake box

[fredom dsm]

Hello guys! I build this heat shield out of cardboard and then MDF but I want the final product to be made out of aluminum. Is there anyone here that can take on this task for me. Please PM me if anyone is willing to help me out.

Thanks.

 

[AWD-Tony]

Use aluminum sheets

 

[fredom dsm]

Use aluminum sheets

Yes Sir, thats what I want but I need somebody to cut them and weldthem together. Thanks

 

[KilleRabbit]

Hello guys! I build this heat shield out of cardboard and then MDF but I want the final product to be made out of aluminum. Is there anyone here that can take on this task for me. Please PM me if anyone is willing to help me out.

Thanks.

Have you considered sourcing a sheet of aluminum and cutting and folding it like a box pattern with end tabs and riveting it together with a high temp sealant in the seams?
I used to be Helo mechanic and we never welded aluminum parts like this. Folded tabs with proper rivet rows is a cheaper alternative if you cant weld it yourself and in my opinion adds a pretty cool aesthetic to the part. If youre interested in trying this method let me know and Ill see what I can do to help guide you through doing it properly so the rivets won't work loose on you.

 

[techboy]

Nice little design you got there. Good work. My recommendation would be to just hit up the Google and find a local fab shop in your area. Your profile says Dallas - there's got to speed/fab shops down there somewhere. Take them your box and somebody will do it for you. Be prepared to pay though. Custom work for a small side job might be a little pricey.

EDIT: Been a long time since I've seen a Dejon Tool pipe installed on a dsm. That goes back old school.

 

[KilleRabbit]

I don't know your exact dimensions but you shouldn't need to weld something like that, just bend it against the grain and you should be good. Pardon my rudimentary sketch, drawing was never my strong suit.

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Here are a couple sources to help should you decide to do it yourself
http://www.custompartnet.com/calculator/bend-allowance

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[fredom dsm]

Have you considered sourcing a sheet of aluminum and cutting and folding it like a box pattern with end tabs and riveting it together with a high temp sealant in the seams?
I used to be Helo mechanic and we never welded aluminum parts like this. Folded tabs with proper rivet rows is a cheaper alternative if you cant weld it yourself and in my opinion adds a pretty cool aesthetic to the part. If youre interested in trying this method let me know and Ill see what I can do to help guide you through doing it properly so the rivets won't work loose on you.

Uuhm!thats a pretty good idea!

Nice little design you got there. Good work. My recommendation would be to just hit up the Google and find a local fab shop in your area. Your profile says Dallas - there's got to speed/fab shops down there somewhere. Take them your box and somebody will do it for you. Be prepared to pay though. Custom work for a small side job might be a little pricey.

EDIT: Been a long time since I've seen a Dejon Tool pipe installed on a dsm. That goes back old school.

Thanks! I cant wait to see the finish product.
I had a FP intake pipe but is too short for what I wanted to do.

 

[KilleRabbit]

Uuhm!thats a pretty good idea!

Thanks! I cant wait to see the finish product.
I had a FP intake pipe but is too short for what I wanted to do.

If you get me the exact measurements I can mock up a print with detailed instructions on how to do it yourself (It may take a day or two). Its not hard and really not all that time consuming you just have to be gentle.

 

[fredom dsm]

If you get me the exact measurements I can mock up a print with detailed instructions on how to do it yourself (It may take a day or two). Its not hard and really not all that time consuming you just have to be gentle.

Ok, Sounds good. Thanks for the help!!

 

[AWD-Tony]

Most likely it’ll have to be at least two pieces for install and removal purposes. And as techboy mentioned, it’ll be costly to have someone fab it and weld it. You can spend $20-$30 at Lowe’s and make your own since you have the templates already. Only thing you’ll have to learn is how to make straight bends which isn’t that hard.

 

[AWD-Tony]

Make a 1” wide 90 degree bent on the top of the bottom piece so you can screw the top part onto it. Then somehow secure the whole thing. Send me the templates and $50. I’ll send it back in a few days

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[Boomdeeze]

I've always considered doing this and running a hose from the passenger foglight hole to the SMIC hole to force air in. If you do tackle this, you should post post up a how-to!

 

[fredom dsm]

I've always considered doing this and running a hose from the passenger foglight hole to the SMIC hole to force air in. If you do tackle this, you should post post up a how-to!

Yes, that is exactly what I want to do. I’ve bought the material to do the bottom just need to find the time to do it.

Make a 1” wide 90 degree bent on the top of the bottom piece so you can screw the top part onto it. Then somehow secure the whole thing. Send me the templates and $50. I’ll send it back in a few days

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Thanks for the help. I try to do that as soon as I get a chance.

 

[KilleRabbit]

Make a 1” wide 90 degree bent on the top of the bottom piece so you can screw the top part onto it. Then somehow secure the whole thing. Send me the templates and $50. I’ll send it back in a few days

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He could also set it up like this so that the hardware is more well hidden

 

[AWD-Tony]

I have to redo mine. Previous owner did it but it’s not completely sealed. Top is pool noodle

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[KilleRabbit]

I have to redo mine. Previous owner did it but it’s not completely sealed. Top is pool noodle

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That's kind funny.
Clever concept, not so practical real world.
Gotta hand it to them for originality though. That's the first time I have ever seen that.

 

[AWD-Tony]

I’d guess it works well. OPs would be more ch more efficient. They also ran dryer vent tube from p/s fog light opening to the hole under the air filter. Kinda ghetto though but she’s not going win a car shows any time soon.

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[AWD-Tony]

Fredomdsm. They also sell 90 L brackets so you wouldn’t need to bend the sheet. Just have to cut to shape if you go that route.

Good luck and post a pic when it’s done.

 

[fredom dsm]

Fredomdsm. They also sell 90 L brackets so you wouldn’t need to bend the sheet. Just have to cut to shape if you go that route.

Good luck and post a pic when it’s done.

Yes, I think instead of welding it, thats what im going to use. Ill just rivet the three things together. The two aluminum plates/sheets to the L brakets. It should work just fine. Will post pics once its all done.
Thanks for all the great ideas guys!

 

[99OZDSM]

I made mine out of Aluminum 6061 with a small bender. Also wrapped the box in DEI CoolTape. Honestly though I should have made the box out of a different material. Aluminum conducts heat easily and therefore would allow heat into the box easier. This is why OEMs use plastic for their intake boxes. I also have a tract from the SMIC opening to the bottom of my air box.

Anyway I mocked up the box with cardboard first, and used the sticks to find the ideal height to seal with my hood.

 

[fredom dsm]

I made mine out of Aluminum 6061 with a small bender. Also wrapped the box in DEI CoolTape. Honestly though I should have made the box out of a different material. Aluminum conducts heat easily and therefore would allow heat into the box easier. This is why OEMs use plastic for their intake boxes. I also have a tract from the SMIC opening to the bottom of my air box.

Anyway I mocked up the box with cardboard first, and used the sticks to find the ideal height to seal with my hood.

Thats nice! What thicknes did you use?

 

[99OZDSM]

Thats nice! What thicknes did you use?

I forget to be honest. I can hit it with calipers and let you know.

 

[fredom dsm]

I forget to be honest. I can hit it with calipers and let you know.

Naah you really dont have to, I was just wondering what others were using. I went ahead and bought 1/8 of an inch aluminum sheets. I think its going to be a Little thick for what I want to use it but I’ll make it work. We’ll see.

 

[pksystems]

I made mine with carbon/epoxy over a styrofoam core that was removed later. Yours is a much simpler shape.

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[fredom dsm]

Ok, here is an update of what I have done. Here are a couple of pictures of the progress.
Thanks