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$3.95 DIY Heat Shield for Cold Air Intake
I threw on a JDM "cold air intake" filter kit and was pleased with the results, but I realized there probably wasn't much "cold" air being sucked into the intake system. Take a look at the "BEFORE" pics and decide for yourself:
http://www.gearfx.com/ford/images/in..._shield_05.jpg http://www.gearfx.com/ford/images/in..._shield_06.jpg http://www.gearfx.com/ford/images/in..._shield_07.jpg |
To optimize my truck's performance, I decided that I would need a heat shield to isolate the intake from the hot air in the engine compartment. I didn't want to pay the money for another tuner's cold air kit, and the homemade heat shields I have seen posted on the forums have looked like a fun and affordable alternative. I considered fabricating my own heat shield from various materials, including aluminum sheet metal, carbon fiber, and various plastics. Carbon Fiber is too cost prohibitive, and I don't have access to a box press and spot welder so I eliminated aluminum. Plus measuring, trimming, folding, and welding all that metal didn't really excite me (nor laying up a fiber composite in a mold, etc). I was feeling CHEAP and LAZY, and if I was going to go through all that trouble, I would rather buy a "real" heat shield. I knew I was going to document my project's success/failure here on the forums, so I was determined to make something simple that was easy to reproduce. I was walking down the aisles in Home Depot when I struck gold: a black plastic Rubbermaid 2956 waste basket:
http://www.gearfx.com/ford/images/in..._shield_08.jpg http://www.gearfx.com/ford/images/in..._shield_09.jpg |
I know what you're thinking, but hear me out! :) The overall shape and size of this little trash can seemed "just right" for my application (meaning: minimal modification for lazy people like me). The 1/8" thick plastic is probably a little thin for optimal heat insulation, but it would be easier to cut and should be better than nothing (preliminary results posted further down). Rubbermaid claims this tough product will resist stains, chemicals, heat (not sure how much), and all kinds of abuse. In addition, the plastic is molded in black with nice rounded edges, so I wouldn't need to paint or refinish my heat shield when done. And who can't resist the price: $3.95! I figured: "Hey, if I screw up, I'll only be out $4, right?"
When I got home I placed the trash can on top of my intake to gauge exactly how much "modification" would be necessary to make my heat shield fit. After positioning the Rubbermaid in different orientations, I found one way that I thought would work nicely: http://www.gearfx.com/ford/images/in..._shield_14.jpg http://www.gearfx.com/ford/images/in..._shield_15.jpg |
http://www.gearfx.com/ford/images/in..._shield_16.jpg
Not yet discouraged, I proceeded to remove my intake filter and took some rough measurements. I concluded that it was possible to transform my Rubbermaid into a heat shield, or waste my afternoon and $4. For those who would like to replicate my madness, I have outlined the rest of my steps below (all disclaimers apply - no guarantees!): http://www.gearfx.com/ford/images/in..._shield_21.jpg I determined that the 4" hole for the MAF should be cut approximately 2.5" from the edge of the trash can bottom (center @ 4.5" from edge). Using a compass, I marked the point of no return: http://www.gearfx.com/ford/images/in..._shield_23.jpg |
... and then used an Exacto knife to carefully cut the hole:
http://www.gearfx.com/ford/images/in..._shield_25.jpg The neighbors were frowning at me, so I took the trash can back to the truck to put the skeptics to rest: http://www.gearfx.com/ford/images/in..._shield_28.jpg http://www.gearfx.com/ford/images/in..._shield_31.jpg |
http://www.gearfx.com/ford/images/in..._shield_32.jpg
Obviously, I was going to have to do some more trimming. After taking some more rough measurements, I started making small cuts in the trash can with a Dremel to provide clearance for the cruise control and expansion tank: http://www.gearfx.com/ford/images/in..._shield_34.jpg http://www.gearfx.com/ford/images/in..._shield_35.jpg |
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To arrive at the final shape, I used a pencil to mark approximate clearance obstructions, trimmed off small conservative pieces of plastic, then went back to the truck to verify my adjustments. The trickiest part was trying to match the contours of the hood, and I used a flashlight to watch my clearances as I open and closed my hood several times. After several iterations of trimming and measuring, I had finally created a heat shield that snugly fit the engine compartment:
http://www.gearfx.com/ford/images/in..._shield_39.jpg http://www.gearfx.com/ford/images/in..._shield_40.jpg http://www.gearfx.com/ford/images/in..._shield_41.jpg |
http://www.gearfx.com/ford/images/in..._shield_42.jpg
Since I didn't document any of the final measurements (I was adjusting too frequently and would have lost track anyway), I took the following orthographic views of the finished product. Hopefully, someone else can use these reference photos to duplicate the general proportions and save some development time (although every truck is slightly different, and adjustments +/- a half inch or so should be expected): http://www.gearfx.com/ford/images/in..._shield_43.jpg http://www.gearfx.com/ford/images/in..._shield_45.jpg |
http://www.gearfx.com/ford/images/in..._shield_46.jpg
http://www.gearfx.com/ford/images/in..._shield_47.jpg If people really care, I may take some real measurements and post them later. This is how the modified Rubbermaid fits in the engine compartment: http://www.gearfx.com/ford/images/in..._shield_49.jpg |
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http://www.gearfx.com/ford/images/in..._shield_53.jpg
After sanding down and smoothing out any rough edges, I started to re-assemble the intake. I first slid the Rubbermaid over the MAF/JDM intake collar: http://www.gearfx.com/ford/images/in..._shield_56.jpg http://www.gearfx.com/ford/images/in..._shield_57.jpg |
Then I installed the MAF back into the rubber boot and verified that everything fit properly:
http://www.gearfx.com/ford/images/in..._shield_60.jpg http://www.gearfx.com/ford/images/in..._shield_61.jpg http://www.gearfx.com/ford/images/in..._shield_62.jpg |
http://www.gearfx.com/ford/images/in..._shield_63.jpg
http://www.gearfx.com/ford/images/in..._shield_64.jpg To accommodate the air charge temperature sensor (and wiring), I had to make a couple more modifications to the Rubbermaid. I drilled a hole in the rear-bottom corner large enough to fit the plastic wiring conduit snugly (it was around 5/16" but your diameter may vary as the conduit is wrapped with electrical tape). I then made a diagonal cut with the Exacto knife (to maintain the smallest kerf and tightest seal) from the 4" intake hole to the 5/16" hole: http://www.gearfx.com/ford/images/in..._shield_66.jpg |
Badass! :bows: :bows: :bows:
Awesome job! |
I eased the 2 wires for the air charge temperature sensor through the diagonal slice until the plastic wiring conduit completely plugged the 5/16" hole. The following photo illustrates the final position for the wiring harness:
http://www.gearfx.com/ford/images/in..._shield_69.jpg I re-installed the air filter and tightened everything up for the maiden voyage. This is what the Rubbermaid looked like in its new home: http://www.gearfx.com/ford/images/in..._shield_72.jpg http://www.gearfx.com/ford/images/in..._shield_73.jpg |
http://www.gearfx.com/ford/images/in..._shield_74.jpg
http://www.gearfx.com/ford/images/in..._shield_75.jpg To make the top edges cleaner, and to ensure a tight seal against the hood, I ran one 3-foot tube of standard foam pipe insulation around the top lip of the heat shield. I hope this stuff is safe - it's supposed to be able to handle some pretty high temperatures when in direct contact with copper tubing, so I hope it will be able to withstand the hot air in the engine compartment without melting (someone please let me know if they think these foam tubes aren't appropriate here. Rubber weather-stripping may be better for this application?). One tube happened to be just enough, but you may want to score the corners to make the 90-degree bends cleaner than mine: http://www.gearfx.com/ford/images/in...shield_75b.jpg |
Eh... I know it doesn't look as elegant (the foam doesn't quite follow all the curves of the heat shield until the hood is closed):
http://www.gearfx.com/ford/images/in..._shield_76.jpg http://www.gearfx.com/ford/images/in..._shield_77.jpg http://www.gearfx.com/ford/images/in..._shield_78.jpg |
http://www.gearfx.com/ford/images/in..._shield_80.jpg
http://www.gearfx.com/ford/images/in..._shield_82.jpg That's it! Time Needed: 2.5 hours Materials Needed: (1) black plastic Rubbermaid 2956 waste basket (1) 3' tube of foam pipe insulation (Optional) (1) pencil or pen to mark cutting guides (1) Exacto knife (1) Dremel or similar cutting instrument (1) tape measure (1) drill with 5/16" bit - some paper towels or rags to wipe off dust CONCLUSION? Well, all I know right now is that it passes the "Stink" test (the Rubbermaid hasn't melted or disintegrated yet, and only smelled funny for a few seconds after initial warmup). I drove 30 miles at varying speeds (ambient temps around 45 degrees F) and when I stopped and checked, the front side and bottom of the heat shield were cool to the touch, and the back corner was barely warm. I need some temp sensors to get some true scientific readings from inside and outside the heat shield, but I think this little setup is probably helping somewhat. The clearances around the cruise control, expansion tank, and fender well are pretty tight, so if any warm air is being drawn from the engine compartment at any "cracks" - it's got to be way less than using an open exposed element. At the least, it's probably keeping the fan wash out. I didn't feel any change in throttle response, performance, or noise, so that's a relief. :) I have one question for those using the JDM cold air intake kit. Are you all using the supplied foam boot? Mine doesn't seem to be doing anything besides further reducing airflow from the fender hole. All input, comments, suggestions, and flames are welcome. I am happy with my low-budget mod, but I know this heat shield could probably stand some improvement. UPDATE: FWIW, I finally did get the rubber weatherstripping (from a Dodge Caravan donor - I know I know.... not a genuine Ford part!): http://www.gearfx.com/ford/images/in..._shield_83.jpg |
Thats a great idea, I've been thinking about makeing one out of Aluminum, but havn't found the time. With the trash can, I now think I can make something. I have the wider cone style filter, so might have to find a bigger can and modify some. One idea, if the heat does get a bit hotter for the trash can, you might could rivit some flat peices of thin aluminum to the outside, leaving a small air gap between (closest to the motor) and that might block some heat.
Now, I just need some material to have a ram air set up. I've been thinking about some of the RV sewer hose, but not shure how that would be, or the aluminum flex duct for heaters and such. Any ideas? |
I want one :D You need to start making them.
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PhillipSVT, you may be on to something. In the spring, I may add some aluminum flashing to the outside as you suggested. I want to take some temp readings to baseline this mod before I do anything else. (Anyone with equipment willing to help out locally?)
I'm not sure which kind of ducting is best. BUt it would be easy to modify this design by drilling a hole in the bottom of the heat sink enclosure and attaching tubing/hosing for the "ram air" setup you describe. :) |
You totally destroyed that trash can! jk...
Looks awesome, you're as handy in that as you are in photoshop!...Anyone else think this is photoshopped besides me? Good job! :thumbsup: |
Congrats man, that is a great idea, ive wanted a cold air set up for a while but didn`t have the extra 200 dollars to buy one. I thinl that you can further improve your heat shield with a fresh air hose running from behind the front bumper to the bottom of your heat shield, to provide more cold air to the filter.
Larry. |
....... it looks like someone needs some thing more productive for theyre sundays. lol :rolleyes: Anyway, cool idea. But i would definately consider getting a ram air setup into that thing. Based on how you made it (and how handy you are with a trash can) im sure you can make something that actually gives you a decent gain.
At first i thought you were kidding but acutally it turned out quite nice. :devil: |
Could you post some pics of it?;) J/K nice job
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makes me want to stop by home depot after i get done working overtime.
[edit] Hey I got an idea. If you like I can send you a cd of mine (all 99 Lightning street/strip action from yours truly) if you would email the dimensions to me.:beers: I am too lazy to firgure it out (its winter time) and I want to get rid of this extra cd jambpaked with fun times.:bandito: |
Excellent Job BMWBig6
I like it, I like it, and I think I'm gonna steel your idea for my next one. Looks a hell of a lot better than my home made first attempt https://www.f150online.com/galleries...2125-33929.jpg https://www.f150online.com/galleries...2125-33930.jpg https://www.f150online.com/galleries...2125-33933.jpg |
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https://www.f150online.com/galleries...2125-33935.jpg
Excellent Job :thumbsup: You've given me some great new idea's :beers: Let us know if it holds up over time |
Looks good. Always glad to see new ideas.
One suggestion. I used the black gasket off the wiper cowl when I did that to my JL box. Since I swithched to the Street scene wiper cowl it was just laying around. I did not use the whole piece though. You could probaly take the OEM one off , put it on the box and put the remaining back on. It would definately look more factory and its FREE!!! Just a suggestion. NICE JOB. Here is a pic of the gasket I am talking about https://www.f150online.com/galleries...1645-30919.jpg |
BMWBig6
This is one of the best threads that I have read in a long time. Well done, well documented and prob a very good cheap way to make sure you are getting cold air..
What would work, seeing that you have a computer (Epson box in one photo) it that you could remove the can, wrap the bottom with one piece of paper and the sides with another. Then use that as a template to mark where you made your cuts in the trash can. Scan the image into Adobe and post it here for all to use and enjoy.. Heck, we can even name it after you.. But some may have an issue with having a BMW part on their L... LOL j/k Great work.. :rocker: Dana |
WOW!
Always nice to see true ingenuity. What I like is that although it's homemade, it looks really good. Now I bet lots of "Ls" will have the "Rubbermaid Wastebasket Mod" in their sigs. Ford dealers can void your warranty for the Rubbermaid mod.!
But hey...that gives me an idea. Take the same wastebasket, cut a 6" hole in one of widest sides, then a matching hole in the hood. Next, get some bungee cords and strap the basket over the hood hole, running the bungee cords from one side of the hood, over the basket, then clip to the other edge of the hood: Instant Ram-Air Hood! On second thought...maybe not. :D (Kidding!) |
Major props for the idea.
It looks better than some of the aluminum ones out there. :thumbsup: |
Rob02Lighting, I like how yours turned out - very nice craftsmanship. Do you like the metal finish, or are you going to paint yours black too?
dboat - that is an excellent idea! That should be a lot easier than measuring every dimension. jaymz - I think you're on to something there! :devil: I have already decided to try a few more things for version 2.0: - substitute black rubber gasket or weather-stripping for the tube foam insulation (a la VINNIE) :rocker: - cut a hole in bottom of heat shield, and route some kind of ducting or tubing for more cold air Anyone want to recommend the best material for the tubing? I have seen vacuum hose, smooth hose, PVC, HVAC ducting, gutter tubing, etc. Would smooth tubing be better than ridged solutions? Also, should I throw out the foam boot stuck in the fender hole (part of the original JDM kit)? Thanks for the all the comments and input thus far! |
I did the same thing about a year ago. Ended up buying 2 trashcans before I got it the way I wanted. I took rubber vacuum hose and used a razor blade to make a cut longways and used that for the trim. Just be careful not to slip and cut your finger (the voice of experience talking)
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nice work with the can!:thumbsup:
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Nice job, but I think I'll stick with my JLP kit.
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Tundra, I'll let you know if I am interested after I finalize some of the details... I don't think I want to make another one, but who knows how I'll feel next weekend. :)
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wow that was almost MaGyver like!!! excellent work! i like the look of the can w/o the grey piping but that's jmo. the piping is too "foamy-looking".....
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