Intercooler Duct Fabrication.
 

Started a fun little project this morning. I have a SR Motorsports intercooler and the stock messed up duct is definitely not pushing the proper amount of cool air through it, most of it is escaping around it. Here's an old picture:
https://i37.photobucket.com/albums/e...S/100_1449.jpg

Even though the duct isn't fully in the pic you can see it doesn't line up and there's a massive square hole in the top of it. Started making templates tonight to close off and extend the duct so the only place the air has to go is though the intercooler.

https://i37.photobucket.com/albums/e...S/100_0059.jpg
https://i37.photobucket.com/albums/e...S/100_0060.jpg
https://i37.photobucket.com/albums/e...S/100_0061.jpg
https://i37.photobucket.com/albums/e...S/100_0062.jpg
https://i37.photobucket.com/albums/e...S/100_0063.jpg

Template attempt #2 came out quite well, just a few more tweaks I we should be good to transfer it to the tin.

Blargz!!!!!
https://i37.photobucket.com/albums/e...S/100_0071.jpg
https://i37.photobucket.com/albums/e...S/100_0070.jpg
https://i37.photobucket.com/albums/e...S/100_0072.jpg
https://i37.photobucket.com/albums/e...S/100_0073.jpg
https://i37.photobucket.com/albums/e...S/100_0067.jpg

have to hold it in place (ducts are usually bolted to the intercooler as this one will be) fits great so far!

Nice work. What gauge of sheetmetal did you use?

dunno found it at the hardware store and said "yep, that will work" might be 14ga galvanized though.

http://i37.photobucket.com/albums/e5...S/100_0075.jpg
http://i37.photobucket.com/albums/e5...S/100_0077.jpg
http://i37.photobucket.com/albums/e5...S/100_0078.jpg

finished, passenger side doesn't line up quite right something must have shifted when I pulled it together with the rivets. Proper use of duct tape!

On the next trip to the hardware store why don't you pick up some aluminum sealing tape? :)

i like

I was thinking the same thing...

I like it! Good job man! damn... I called that skillz!

Hey pretty cool. :)

Who would of knew sheet metal work would be the remedy? Hahaha that's a cool lil project. That was thoughtful in using cardboard as a template... edges look sharp tho. You probably already filled it down, but if not, that might be a good idea. 2 thumbs up for the project :)

I like it man... Good inspiration for me on what I should do.

Looks good. Might want to wrap it in gold foil or some other heat-rejection materials, since a metal duct with hot radiator air blowing at it will transfer some heat.