$75 custom intake w/ Heat shield

Parts list:
- 3' X 2' 28 gauge sheet of sheet metal - (HomeDepot) $10
- 8' section of steel elbow bracket - (cheap, thin type) (HomeDepot) $5
- Cast Iron heat resistant spray paint - (dark grey, flat) (HomeDepot) $4
- Black synthetic carpet - (like speaker box covering) (Bargain Outlet) $10
- Garage door weather seal - (large rubber gasket type) (sears HW) $6
- Cone filter - (AutoZone) $25
- 60deg intake elbo + 3"-2.5" coupling - (AutoZone) $10
- Misc nuts and bolts - (Sears HW) $5

First I constructed a prototype out of cardboard.
Dotted lines are folds and solid lines are cuts
[IMG]local://upfiles/2294/BB91576CDEC647409243B953C10D92B2.jpg[/IMG]

After trimming the prototype to fit height wise, I flattened out the prototype, traced it onto the steel, and cut out with large tin snips.

Folded up the steel version and used the metal elbow brackets to secure the corners
Spray painted with the high heat paint.
Bolted the carpet to the outside.
Bolted the rubber gasket to the top.

[IMG]local://upfiles/2294/E6C5B32350BA40129AAB4C8CFD2B5B5C.jpg[/IMG]
[IMG]local://upfiles/2294/84DB9A254E454C7F8637BE2D64F7BF3E.jpg[/IMG]
[IMG]local://upfiles/2294/EF4B2F43EBB94B7586398B6B133C435E.jpg[/IMG]

Fitted the finished product into the engine bay. I used the stock cold air IN from the stock airbox.
I used the Elbow bracket to secure the front and back of the shield to the side of the engine bay.

[IMG]local://upfiles/2294/6A91329A3EA949A1B689F422EC2D07EB.jpg[/IMG]



MORE PHOTOS can be seen here, Clicky

 

From what I can see in the small pics here at work on this ****ty monitor it looks nice. At home hopefully the pictures wont look so dark.

NICE JOB! What was the carpeting used for anyways?

 

The synth. carpet was for added heat resistance. I have a custom ECIS (east coast induction systems) intake on my BMW, and I used the same material they used on that heat shield. It wraps around the outside of the whole structure.

It was pretty hot and humid today, and I have a 30min drive to work. With aggressive driving on my way in --I immediately popped the hood, the filter was COLD to the touch, and the inside of the heat shield was barely warm at all.

Vroom Vvroom PPSSSHHHHHHH !!
love it

 

Now buy a BOV for your car and buy KEVINS (Member on Volvospeed.com (TheUnderlord, is his name)) blanking plate for the CBV.

 

The CBV sounds okay for now. I'd love a BOV if the car was a manual trans. My wife was like "What's that 'PSHHHH' sound from the Volvo?" HAHA!
I think exhaust will be the next mod...then suspension.

 

Looks Awesome!!

What did you end up doing with the Air pump hose?

 

Right now I just have it sticking up next to the heat shield. I'm going to purchase a small cone filter the same color as the one I used for my intake and rig it up to the heat shield. Should look pretty cool.
Now my dad wants one for his 850R...

Next job is to Clean the Engine BAY!!

 

Cool clean looking job.

One day I will make something like that for my car.
But with the Cowl hood it is hard to do.

 

That is sweet looking, well done! I want to make one of those...