Fab'd a Heat Shield
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Intermediate
Joined: Jun 2006
Posts: 408
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From: TX
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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Thread Starter
Intermediate
Joined: Jun 2006
Posts: 408
Likes: 5
From: TX
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.
Good job. 
My skin gets really itchy everytime I am near someone who is working on fiberglass.
Maybe JPI can make that heat shield for members here.
Something like this Nomura one will be awesome for you guys.
My skin gets really itchy everytime I am near someone who is working on fiberglass.
Maybe JPI can make that heat shield for members here.
Something like this Nomura one will be awesome for you guys.
Thread Starter
Intermediate
Joined: Jun 2006
Posts: 408
Likes: 5
From: TX
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.