Turbo Heat Shield / Cold Air Feed / Cone Filter Install / Airbox Mods

[Jonas_R]

Any chance that you would make a kit with a 4" port and some cool air ducting or something?

[Rusty]

I'm going to sort out a pattern from the heat shield but the ducting is just a 4" piece of aluminium corrugated ducting that I've squashed and shaped into position and made work, it took about 1/5 of a £5 piece of pipe from the local hardware store. The fabric expensive motorsport stuff won't work as well as it's squashed quite a bit at points to cloear some of the brackets. Took an hour to fit (took off the XM pipe and you'll need to remove any plastic gubbins, mine's all in a box) and made a big difference so worth the effort.

Now that I've proved the concept, I'll be spending a bit more time on the air feed to ensure that it's a bit neater and not as crushed in places. The bit that collects the air is 4" though so it takes a big gulp! I want to fit a 4" bass port but it's not quite the right size, I'll have to modify it a little.

[Bram]

Make sure you place the 4" port as low as possible into the airbox, so your airfilter still fits into the box when closing the top cover. BTDT with 4" bass port myself and had to modify it 2 years ago in order to get it working correctly.

Good project dude!

[Rusty]

Cheers Been meaning to sort all this for 5+ years. There's not enough of my airbox left to fit a 4" port into it's for the front of the car to catch more air and shoehorn it into the 4" pipe.

Will see what price I can get on some 180 degree bends and joiners for a kit, I think ideally the setup would use a 90deg, long legged 80mm silicone hose and a 90deg ally pipe, thus ensuring that you can get the alignment right. It's not bad tho, would be better if I'd not rushed the cutting of the 180 deg bend and messed it up a little

[s2_bo]

HAHA, good effort, your airbox looks like you have been using it as a target for shotgun practice.

I like your heat shields and may just adapt your idea for my car a bit.

Nice one.

[Rusty]

Do it This project is for the love so feel free to crib away, it's hardly anything ground breaking... If I can get some heat shields made for reasonable money then I'll get some sorted out.

[Rusty]

Well I think I'm nearly there Got the ECU reset and the car is absolutely flying. 20 deg here today and the heat shield and cold air feed mean that there's no horrible heat soak lag or coughing on WOT like I had before on an open cone, I think it's pretty close to the airbox so just goes to show that a little effort can sort these things out. The 180deg bend on the inlet has quietened the cone down on all but WOT although the woosh on lift-off is quite loud, not atmospheric DV loud but louder than the airbox.

One last heat shield to make and I think it'll be a genuine alternative to an airbox, for those that like a lot more wooshing and whining

[Dobby84]

Looks like Ill be attempting this when the weather gets a little better but think ill be keeping the original air box rather than a cone.

Just a thought, My friend has his down pipe ceramic coated. Could this be applied to the heat shield to improve the heat resisance or is there a better material than ali?

Has anyone put a turbo heat sock type sheild on thier turbo with any effect?

[Rusty]

In terms of the heat shield, a double skin will be much better than any surface treatment and cheaper too; it's just the space and design... There are laminated heat shield materials that would do well. It's as important to get a really good cold air feed to the filter, whether it's cone or 'box, either from the inner wing or grille.

[HPmuirt]

Hey Andy,

What's your plan re the heat sheilds - make them and sell or post the plans up for us to cut out our own from Ali sheet? I am happy with either

I agree that using 2, seperated by spacers would be the way forward, so the plans might want to incorporate different bend points and hole positions (or oval holes) to allow 2 to be created with say a 1cm air gap.

Cheers n

Si

[Rusty]

Been a while since I added anything to this thread but to make up for it, here's a drawing of the heat shield.

It's worth noting that this may require a bit of messing to make it fit, so make it out of card first and adjust with scissors. I had to adjust mine after changing to a Wagner EM and RS2 turbo but it's ally, so easy as pie to bend and shape. It's also worth noting that due to me using 1.6mm ally, I had to turn the edges in 5-10mm to give it strength and do a lot of massaging to stop it hitting anything. 2.5mm ally wouldn't have this problem so much, nor would stainless.

Thus, treat this as a guide rather than a foolproof plan.

All that aside though, this is a great little mod for the cost of some ally sheet and a hacksaw blade

[vonbeck]

just been reading through this must have missed it first time round ,and fancy a go at something like this myself whats the benefit of resetting the ECU? As you have done quite a few times

[Rusty]

When I was swapping between the airbox and cone, I was using different MAFs

[vonbeck]

ah thats ok then

[Rusty]

Cheers, glad you approve

Let me know how you get on with the heat shield