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Hi all, Just completed my CAI and heat shield on the weekend and figured I'd post up some pics. Unfortunatly I didn't think of this when I was actually making and installing it, but its not rocket science so you'll get the idea :)

Materials Used

Petrol Funnel (bought from local servo) $5

100mm AirCon Duct (breeze-air shop, scrap from old install) $?

2 X "600mm x 300mm x 3mm 602 grade aluminium sheets" (Local aluminium wholesaler) $30

10mm 90 degree aluminium edging $3

Rubber Edging

Zip Ties

Duct Tape

bit of 16mm conduit

pop rivets

and a some free time

Method

Started off by cutting the funnel to suit the size of the air duct, then used duct tape :down: to secure it to the funnel. Due to my Front mount only using one of the stock intercooler holes I was able to utilize the other one. I zip tied the air duct to the back intercooler hole and used a bit of conduit around the edge to hold it in properly. I mounted the funnel to the fmic piping in the bottom right cut out of my kit.

post-62690-1246932818_thumb.jpg post-62690-1246932760_thumb.jpg

Next was the Heat shield, After reading through many of the cai threads, figured I'd go with the cardboard templates to get the shape. After a bit of stuffing around trying to get it to fit, I traced the template on to the aluminium and started cutting, probably could have gone for a thinner alluminium cos it took a while to cut and file it to size. Once that was done, pop riveted the 90degree angle stuff to the edge to hold the final product together. Added a bit of rubber edging and easy as that.

post-62690-1246932792_thumb.jpg post-62690-1246932771.jpg post-62690-1246932805.jpg post-62690-1246932742_thumb.jpg

Hope this may help anyone looking to go down this road.

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https://www.sau.com.au/forums/topic/278106-another-caiheatsheild/
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