The lettering on the rear left tire. It not enough to even mark the tire.

 

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.

 

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.

 

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.

 

It fits nicely and directs all airflow through intercooler and rad.

 

View of ducting inside of installed bumper.

 

Impressive, thanks for the pics and the explanation!. Any chance you have data logs of temps from before to compare?

 

I can has duplicate? ^_^ Nice work, man.

 

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.

 

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.

 

I have this nice political sign to use.

 

That might be too thick to manipulate when making patterns. I use cardboard from cereal boxes and the light cardboard from document folders.

 

What tools did you use?

 

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.

 

A+ would read again.
I need to get a nibbler.... they are boss apparently.

 

Here's your boss Nibbler:

 

very nice. maybe I missed it: what size sheet of alum did you end up needing?

 

It was scrap from a friend. The sides were about 10" x 14" and the bottom was 30" x 9"

 

Looks good as usual 99

 

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.