Fab'd a Heat Shield
07-05-07, 06:05 PM
#1
Intermediate
Thread Starter
Fab'd a Heat Shield
I've been looking everywhere for a heat shield to use with my Injen intake, but haven't found one anywhere, so I decided to make my own. Tried to figure out how to do it with aluminum, but the complex shape needed stumped me, so I decided to make one in fiberglass. I used the stock airbox as a form, and made a paper mache mold; used 2-part marine flotation foam in the paper mold; shaped it; bondo'd it; sanded (a lot); fiberglassed; and this is the result.
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07-05-07, 06:16 PM
#8
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There was a lot of shaping of the foam form required and it needed to be put in and out of the engine compartment for sizing. This took far longer than I imagined, but I'm pleased with the results. I'm still looking for the right rubber molding to cover the edges.
07-06-07, 07:44 AM
#15
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Thread Starter
Thanks guys. Believe me - I would have preferred to just write a check for this, but the experience was interesting. Now, of course, I am seeing ways that the design could have been better......
Oh - the gray color against the engine is high temp paint that has "ceramic" material in it (maybe...), and the black paint is crinkle paint - to hide those fiberglass imperfections.
The picture of the shell as it was broken from foam mold was just the start of the fiberglassing process, as I had to use glass mat to build up the strength of the part after I had the correct initial shape.
Oh - the gray color against the engine is high temp paint that has "ceramic" material in it (maybe...), and the black paint is crinkle paint - to hide those fiberglass imperfections.
The picture of the shell as it was broken from foam mold was just the start of the fiberglassing process, as I had to use glass mat to build up the strength of the part after I had the correct initial shape.