BMWBig6

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:







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:

__________________
Ben - NLOC #780; Cracked foglight mod; Synthetic tire air; Automatic brake dust; Extra-density fuel guage needle; SVT cupholders; Chip in clearcoat (street program), The Force intake lube/MAF cream; Pegged MAF

BMWBig6

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:







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!):



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:



... and then used an Exacto knife to carefully cut the hole:

BMWBig6

The neighbors were frowning at me, so I took the trash can back to the truck to put the skeptics to rest:







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:

BMWBig6

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:









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):









If people really care, I may take some real measurements and post them later.

BMWBig6

This is how the modified Rubbermaid fits in the engine compartment:











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:

BMWBig6

Then I installed the MAF back into the rubber boot and verified that everything fit properly:











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:



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:

BMWBig6

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:

BMWBig6

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:













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. 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 a "ram air" setup too.

UPDATE: FWIW, I finally did get the rubber weatherstripping (from a Dodge Caravan donor - I know I know.... not a genuine Ford part!):

jschuepb

BMWBig6,

You are my hero!
I have been working on the cold air side of this kit.... sorry no digital camera but I too walked through home depot.
I bought a huge 3 inch vacuum cleaner end piece for 9.99... yea too much. Used a dremel to carve it out and a propane torch to heat it up and make the opening 2 inces from top to bottom.
Next I found some nice 3ft aluminum flex tube and an attachement to mate to a heat shield.....
But I just couldn't figure out the heat shield part, that is till now.
A trash can, this is so sweet.
I will try to get my digital camera working but I have a vacuum cleaner attachment and some aluminum tubing running below the intercooler inside the driver side fender under the powerstack filter. I have been going nuts trying to figure a good piece of flexible plastic to make a heat shield till now....
This is awesome. Hope to post pics soon.

Jon

Wht95L

When I first saw that waste basket sitting on your aircleaner, I am sorry but I damn near lost it.
But my laughter was premature. That is some mighty fine fabrication you've done there. Unless you can see the word Rubbermaid somewhere, nobody would ever know unless you told them.
YOU ROCK!

__________________
White 95 L #1669 of 2280
Original Owner

Just hit 57k miles on 6-18-03

Nosdog2

You are the man!! You shounld be put in for Lightning Inventor of the year. I have the same Air Kit and think that this looks like a nice saturday project! All I can say in advance is thanks!!

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2001 Black Lightning
2003 F250 Diesel
93 Mustang GT

blowntruck

Looks great and exactly like my Airaid intake but, alot better of a price.

loosebolt

Looks great and thanks for the writeup!

Can I make a suggestion. Instead of the pipe wrap on the top, use a piece of windshield wiper fluid hose with a slit down the middle. Just a little cleaner looking

99SVT

So, when will you have these things for production?

Looks good, been wanting on for some time... think this will work for me as well. Thanks for the details.

Jer

TimBurntire

This should be included in the "ingenious devises" book this year.