Simplicity and efficiency was what I was after and I went with 2mm Aluminium sheets. Aluminium has excellent thermal mass and reflective properties hence its use in insulation batts, reflective sarking used in roofs, etc. This guide is for educational purposes, I will not be held liable if you injure yourself or your things, blah blah blah.
This is what I used:
- Sharp Heavy Duty Scissors (have to be nice and sharp)
- 600mm x 1000mm Sheet of 2mm thick Aluminum ($30 Bunnings)
- Aluminum Roof Sarking (alternatively you can use a reflective sun visor)
- Expandable Insulation foam in a can (Bunnings $10)
- Liquid Nails
- Pop Rivets and Riveter
- Drill
- Small tube of All purpose silicone.
You can always improvise if there is something you don't have.
Here is what I did:
1. Used the scissors to cut the template below out of the sheet of aluminium. Cut really easy like a knife through butter.
Cut out the solid lines only, the dotted lines are where we will fold to make out tabs and edges. (duh
)
2. Once you've cut out the box and its lid, Cutout the hole for the intake pipe to enter through as shown by the orange circle on the diagram.
Fold the template according to this diagram. I used a block of wood and a hammer to square the edges and bend the tabs neatly. Drill the holes in indicated so that you can pop rivet them once the box is all folded up (make sure they line up).
3. It should now look like this, all folded up. Just pop rivet those holes that were made earlier or fasten them with small screws if you don't have a riveter.
4. Now, line the inside with some liquid nails, and then spray a small even layer of the expanding insulation foam on all sides of the box, it should stick to the liquid nails. add a little more liquid nails to the top of the foam and then line the inside of the box with the reflective sarking or sun visor material. I used the reflective roof sarking because I had some lying around in the garage. Remember to also apply some to the back of the lid as well.
5. Now to install it. With the air filter off your intake hose, pop it through the hole in the box and lower the box into the engine bay. Pop your filter back on while the hose is sticking into the box. I put a screw through the bottom of the box to fasten it to the chassis. Place the lid on and fasten it with some screws or whatever you like.
6. Finally, spread some silicone around where the intake pipe enters the airbox to cover the gap. Now your finished.
This is what I got. Will post more pics of the inside of the box soon.
nice and simple indeed
