My new DIY cold air box/intake heat shield.
#1
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The weather is warming up and so are my intake temps. Its time to lose the filter on the compressor laziness and do something better about this. First I just cut a piece of my extra IC piping to move the filter up and behind the headlight. This is my first ever sheet metal project.
Next I started making the box out of cardboard:
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![](http://img.photobucket.com/albums/v618/Wayne_Curr/DSC01078.jpg)
Got my basic shape and stuck some wooden skewers in the cardboard like so:
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If you notice, its got the contour of the hood. I stuck those skewers in there and closed the hood on them to get the shape. Learned this from some DSM forum a while back.
Next I took out the cardboard, traced it onto the aluminum sheet I got and busted out the dremel and went to town.
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Its not DIY without JBW!
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And finally
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So for a few dollars, many dremel cutoff wheels and not too much blood (sheet metal is sharp) and you can make one too! Is it pretty? No. Does it work? Probably. I wanted a complete box like the BEGi one, but my filter is too tall and the hood barely closes as it is.
Next up is a heatshield between the mani and the compressor/inlet pipe.
Next I started making the box out of cardboard:
![Name: DSC01076.jpg
Views: 13940
Size: 141.3 KB](https://www.miataturbo.net/attachments/diy-turbo-discussion-14/205869d1501252558-my-new-diy-cold-air-box-intake-heat-shield-dsc01076.jpg)
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Size: 153.9 KB](https://www.miataturbo.net/attachments/diy-turbo-discussion-14/205870d1501252558-my-new-diy-cold-air-box-intake-heat-shield-dsc01077.jpg)
![](http://img.photobucket.com/albums/v618/Wayne_Curr/DSC01078.jpg)
Got my basic shape and stuck some wooden skewers in the cardboard like so:
![Name: DSC01081.jpg
Views: 10062
Size: 125.6 KB](https://www.miataturbo.net/attachments/diy-turbo-discussion-14/205871d1501252558-my-new-diy-cold-air-box-intake-heat-shield-dsc01081.jpg)
![Name: DSC01082.jpg
Views: 5761
Size: 118.0 KB](https://www.miataturbo.net/attachments/diy-turbo-discussion-14/205872d1501252558-my-new-diy-cold-air-box-intake-heat-shield-dsc01082.jpg)
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If you notice, its got the contour of the hood. I stuck those skewers in there and closed the hood on them to get the shape. Learned this from some DSM forum a while back.
Next I took out the cardboard, traced it onto the aluminum sheet I got and busted out the dremel and went to town.
![Name: DSC01085.jpg
Views: 5183
Size: 119.3 KB](https://www.miataturbo.net/attachments/diy-turbo-discussion-14/205875d1501252558-my-new-diy-cold-air-box-intake-heat-shield-dsc01085.jpg)
![Name: DSC01086.jpg
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Size: 79.8 KB](https://www.miataturbo.net/attachments/diy-turbo-discussion-14/205876d1501252558-my-new-diy-cold-air-box-intake-heat-shield-dsc01086.jpg)
Its not DIY without JBW!
![Name: DSC01087.jpg
Views: 5051
Size: 85.3 KB](https://www.miataturbo.net/attachments/diy-turbo-discussion-14/205877d1501252558-my-new-diy-cold-air-box-intake-heat-shield-dsc01087.jpg)
And finally
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So for a few dollars, many dremel cutoff wheels and not too much blood (sheet metal is sharp) and you can make one too! Is it pretty? No. Does it work? Probably. I wanted a complete box like the BEGi one, but my filter is too tall and the hood barely closes as it is.
Next up is a heatshield between the mani and the compressor/inlet pipe.
#10
Cpt. Slow
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I wouldn't paint it. The aluminum obviously won't rust, and the paint will just flake and chip over time. That's why I love aluminum, it looks pretty bare and won't rust. I'm a big supporter of unpainted valve covers too.
I need to get a smaller filter and do something similar, my filter's right behind the radiator, I hear the air's not very cold there.
I need to get a smaller filter and do something similar, my filter's right behind the radiator, I hear the air's not very cold there.
#13
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thanks for the kind words guys.
#18
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I used to have that problem. Then I invested in a diamond cutting wheel. Had it for a couple of years now and it's as sharp and strong as day one. I highly recommend this - saves you $$ on standard cutoff wheels and saves lots of hassle!
http://www.dremel.com/en-us/Attachme...l.aspx?pid=545
http://www.dremel.com/en-us/Attachme...l.aspx?pid=545
#19
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I used to have that problem. Then I invested in a diamond cutting wheel. Had it for a couple of years now and it's as sharp and strong as day one. I highly recommend this - saves you $$ on standard cutoff wheels and saves lots of hassle!
http://www.dremel.com/en-us/Attachme...l.aspx?pid=545
http://www.dremel.com/en-us/Attachme...l.aspx?pid=545
A word of advice to those doing the skewer trick: my hood isn't closing quite right because I didn't factor in the additional height of the rubber hose. Keep that in mind if/when you build yours. I'm going to have to cut it down a bit, I know exactly where it's too high.
I cant wait to get started on my exhaust heat shielding. I'm still planning it out but I wanna double up the aluminum and put something in the middle.
#20
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awesome! looks good. i wish my piping was routed differently so i could do that too. fyi, i cut lots of alum. sheet for all the little projects on my cars. i tried 6 different methods and nothing worked as good as my buddy's band saw at his work. well, i can't always use that so i had to get something for my garage, but didn't want to spend the $$$ on a band saw. my last hope before spending 399.99 on a band saw was a regular old jigsaw from sears. i was able to find 1 pack of alum. cutting blades and took it home to try it. that jigsaw cut through the aluminum sheet like the proverbial ''hot knife through butter'' total cost - $45.00.