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Old 05-04-2012, 01:40 PM   #301
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The lettering on the rear left tire. It not enough to even mark the tire.
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Old 06-18-2012, 03:29 AM   #302
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This weekend I added ducting for the intercooler and radiator. It channels all the air from the bumper opening. The duct is made from three pieces of aluminum. I first made a template from cardboard then transferred the parts to aluminum sheet.

I used strips of cardboard to make mounting tabs then made the panels and mounted them to the tabs.
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99mx5 EFR build-img_20120613_201853.jpg   99mx5 EFR build-img_20120613_205823.jpg   99mx5 EFR build-img_20120613_213910.jpg   99mx5 EFR build-img_20120613_213931.jpg  
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Old 06-18-2012, 03:32 AM   #303
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Once I made the sides I made the bottom panel to seal the gap between the intercooler and radiator. I then cut the leading edge to fit behind the bumper.
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99mx5 EFR build-img_20120613_231958.jpg   99mx5 EFR build-img_20120613_232052.jpg   99mx5 EFR build-img_20120613_233306.jpg  
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Old 06-18-2012, 03:33 AM   #304
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I transferred the parts to aluminum sheet and riveted them together. It is also shown how it will fit in the bumper with the bottom panel.
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99mx5 EFR build-img_20120615_190239.jpg   99mx5 EFR build-img_20120615_203127.jpg   99mx5 EFR build-img_20120615_203227.jpg   99mx5 EFR build-img_20120615_203211.jpg   99mx5 EFR build-img_20120615_203217.jpg  

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Old 06-18-2012, 03:38 AM   #305
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It fits nicely and directs all airflow through intercooler and rad.
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99mx5 EFR build-img_20120615_205132.jpg   99mx5 EFR build-img_20120615_205156.jpg   99mx5 EFR build-img_20120615_205246.jpg   99mx5 EFR build-img_20120615_205344.jpg  
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Old 06-18-2012, 03:42 AM   #306
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View of ducting inside of installed bumper.
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99mx5 EFR build-img_20120616_210148.jpg   99mx5 EFR build-img_20120616_210826.jpg   99mx5 EFR build-img_20120616_210636.jpg   99mx5 EFR build-img_20120616_211019.jpg  
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Old 06-18-2012, 04:37 AM   #307
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Impressive, thanks for the pics and the explanation!. Any chance you have data logs of temps from before to compare?
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Old 06-18-2012, 11:43 AM   #308
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I can has duplicate? ^_^ Nice work, man.
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Old 06-18-2012, 01:44 PM   #309
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I am actually going to be doing my ducting this afternoon and the next few days. This is a great example of where to start.
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Old 06-18-2012, 06:17 PM   #310
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Thanks for the comments! The trick is to use the cardboard for cutting and fitting. If you cut off too much, just tape some more on again. Try to use factory mounts on the chassis and make tabs, then attach the patterns to the tabs. When you cut the patterns, integrate the tabs to make it all in one piece.
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Old 06-18-2012, 06:19 PM   #311
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I have this nice political sign to use.
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Old 06-18-2012, 07:19 PM   #312
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That might be too thick to manipulate when making patterns. I use cardboard from cereal boxes and the light cardboard from document folders.
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Old 06-19-2012, 12:28 AM   #313
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What tools did you use?
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Old 06-19-2012, 12:44 AM   #314
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I used scissors, tape and a stapler for the cardboard patterns . I used an air nibbler, jigsaw and tin snips to cut the metal. I used a metal brake to bend the bottom panel. I used a drill and rivet gun to assemble the parts.
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Old 06-19-2012, 12:47 AM   #315
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A+ would read again.
I need to get a nibbler.... they are boss apparently.
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Old 06-19-2012, 09:52 AM   #316
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Here's your boss Nibbler:
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Old 06-19-2012, 10:02 AM   #317
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very nice. maybe I missed it: what size sheet of alum did you end up needing?
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Old 06-19-2012, 02:17 PM   #318
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It was scrap from a friend. The sides were about 10" x 14" and the bottom was 30" x 9"
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Old 06-19-2012, 06:51 PM   #319
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Looks good as usual 99
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Old 06-19-2012, 07:19 PM   #320
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Looks good! Do you have air jumping over the IC or is it sealed to the mouth?

I hate that AC dryer thing, I was going to pull mine out. Looks like you found a way to work around it.
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