I finally finished my duct, I still have to add the rubber trim to fit up against the intercooler. The duct was made by fitting cardboard profiles to the duct and over the radiator, undersized for the fiberglass. I then sent the profile off to a hot wire cutter. Had the duct cut out of construction foam. The side profile of the duct was cut and trimmed for the rad support. I fiberglassed over the foam. When I had enough layers, 1 support, 3 finish, I used acetone to eat out the foam.
Should have pics of my custom cross brace and fitment to the IC soon.

Please don't bother posting in the thread if you plan on being negative about the IC.

 

I WANT ONE!! HOw much fritts?? Looks excellent!! Post installed pics asap!!

 

I am using a custom cross brace, koyo rad, and greddy elbow with powersteering so my duct would not be the same as those that used the piping or the stock rad. I have not throught about making any for others much yet. As there was a lot of work that went into making this one. I would need someone elses car to mock one up too.

I also plan on making an extension that bolts up to the stock rebar to focus the air into the inlet.

 

If you're selling, I'm interested!! (Extra motivation?)

That duct looks really good. I might follow your methodology if I get more time.

 

Are you using the stock duct to start the fabrication process or are you cutting above the radiator toward the pass. side to make a completely new and wider inlet for the ducting?

 

I used almost all the space availale under the rad support to the radiator on the driverside. I also lowered my koyo rad lower to get a larger height through that area. The duct then curves over to the passenger side so the ic is located closer to the center of the vehicle. In that position I can still get my battery, honda type, between the headlight and the duct.

So its still in the stock location when compared to the stock duct. But i did not use the stock duct as a pattern as it was out of position when I moved the rad down at the front.

 

That's exactly how I planned to do this, very, very nice fritts. Clean and smooth. good job

 

Wow. So, thats how its supposed to be done. Seriously though it looks great. Better than my modified stock duct.

 

I am building a few out of Alum and they will be up for sale in a week or so.

I will post pics tomarrow after work.

I havent set my price yet but in the range of 100-125

 

Good job ! Glad to see another person custom fabbing air ducts and SHARING.

 

Awesome work

 

I don't know if this will help anyone else but here is a dxf of the profile I sent to the foam cutter. Just a couple of notes, the duct is undersized for the fiberglass and there is a 1 in extension where the duct contacts the core. I fiberglassed it in so that I could change the position if I wanted after fiberglassing. Total width of the cut was 18 inches.

Also here are some sites you could look at to send a profile to. The place that cut mine just went out of business. They did have to cut it into a top and bottom halfs because of maximum cut sizes.

http://www.flyingfoam.com/launch.html
http://www.dbalsa.com/foam_wings/custom_foamwings.htm

 

Here are a couple pictures with the piping installed. I need to clean up the piping a bit but I don't think it looks to bad.

 

Missing a prop rod?

 

Yeah, Plan on using struts anyway after it gets home from paint.