No my car is not an itr. gsr with skunk2 intake manifold along with other stuff ( https://honda-tech.com/zerothread?id=443103 ). I figured that a lot of itr owners have the j's so they might find this helpful.

first step was to make the heat shield/air box. I went to TAP plastics and picked up some extra scrap plastic (5/8'' thick I think) 4 pieces of 16"x20to 28" was under 4 dollars. they only had clear plastic or neon 80's style green. I opted for clear.

Then went to home depot and got some 90* brackets for attaching the pieces of plastic together. I have extra various bolts/nuts/washers at home that will work.
Also picked up 4" air duct that is 36" long.

Started cutting and trimming the plactic after making card board templates that I tested on my car. I made the plactic bigger than the template, then trimmed it down after test fits.

After I test fitted I drilled the bolt holes and assembled the 3 pieces together.




Next was to route the air ducting. this took about an hour because the ducting is very stiff, and needs to be out from the car to be able to bend the ducting. I routed it from the engine bay to beneath the turn signal.


The ducting ended up being too short after I cut off the one piece metal ends that come on it. I am going to have to make some type of extension to get the ducting flush or higher to the bottom of the box.
I decided for short term to just use some duct tape. I will make a carbon fiber extension or farbicate something to make the air duct flush with the bottom.



Next step was to hack a hole in my bumber

My lower portion of the bumper has seen better days with 150k miles on the chassis and many many trips to tahoe driving behind trucks that kick up rocks and other fun pieces of stuff.
If I decide I dont like a hole in my bumper a few months from now, I can pick up a new one from the junkyard. no haters or flamers on the cut a hole in my bumber please.
I first made a template for the shape and size of hole I wanted to cut. But after I started cutting I figured it is easier to just go by eye. I used my dremel tool with the attachement that is a backward drill bit. that was excelent at hacking through the plastic like butter. Then used the round sander piece for smothing and shaping a straight (semi) line

It was pretty easy to cut the plastic bumper, it could be done in under an hour.

I then bought some 1" or 3/4" pipe insulation from home depot for $1.44. this is used to line the top of the box from whatever hot air is trying to still get to the filter.
I drilled some holes through the side of the box and ziptied the insulation over the egde.


I also put insulation where the intake arm rests on the box. Since my intake did not come with a bracket for holding the intake up. now the intake arm is more solid and does not flex as much as before.

I also had extra dynamat laying around. I put a big piece of dynamat on the part that faces the engine. Along with 2 strip of dynamat on the piece that holds up the intake arm.

The 2 main things that need to be done now are to extend the ducting flush to the bottom of the box, and make an air funnel that attaches to the bumber that turns then attaches to the air duct.
I already bought somer carbon fiber sheets and resin for making funnel. I just need a solid days worth of time to make the mold and then the funnel. It might take longer than a day to make it though.
I also might extend the hole more towards the side of the car to let ever more air in. I figure that bigger the hole the better.

 

DIY ghetto rigging =

 

ghetto indeed, but i love the ingenuity. great job!

 

Is that safe?

 

i'm sorry but that just looks like poo.. just my 2 cents..

latz

 

There is no way I would fabricate a box like that to put into my car

 

i'd cut up the stock airbox If i was to do what you were doing. how does it hold up under hard launches and acceleration. jus curious.

 

looks like your home depot ducting got pretty scrunched up!!

gotta luv the plastic heat shield too

 

looks nice for diy, I've been thinking of doing the same thing for my car... TAP plastics also sells weldon 16, or weldon 3 if the pieces are flush, which you could of used to bond the plastic pieces together instead of using the brackets. The glue is easy to apply and it'll probably make the box look better. Less weight too I look forward to seeing how you make the carbon fiber ducting.

Brad

 

Can the J's arm and the Mugen intake be combine for the ultimate sickness combination?

 

nice i love diy

 

don't foget to make hole(s) inside air duct for water to escape

 

When I read " I cut a hole in my bumper" I got scared that it would look like **** but to tell you the truth that hole doesn't look all that bad. Good job by the way.

 

DIY =

(I think I may have started something with this bumper cutting idea )

 

is there a reason why you think it isnt safe?

everything is secured nothing is moving around. the j's intake by itself is more dangerous because of the way it mounts to just the throttle body.

the plastic isnt going to melt. dynamat is rated to very high temps.

designed for performance only, not bling or show car points.
it is under the hood. who looks at it anyway?

I dont think so. the j's intake opening is bigger than the stock intake arm.

it will look better when the duct is put in there.
i will have the carbon fiber extend out, and make a small lip around the hole.

I am going to start making the mold today for the duct. Hopefully it turns out good, and isnt to hard to do.

 

ghetto that bumper cut is hardcore tho


my custom heatshields



[Modified by XDEep, 1:46 PM 3/15/2003]

 

^^ lol

im curious on heat.. that looks really nice BTW. id do it if i had a J's.