| Size |
Caption |
| 144882 |
Here's the problem area. I found three locations to secure a heatshield, marked with red arrows. |
| 120026 |
Using a piece of cardboard I began to create a template. |
| 153248 |
The roughed out template is traced onto a new final template. |
| 149569 |
A LOT of fitting and refitting is necessary to get the angles and holes right. Make some angle templates too. |
| 103697 |
This is aircraft grade aluminum, but any type will do. Make sure it isn't too thin, the bulk doesn't add much weight, but it does add stiffness. I marked out the template with a Sharpie pen. |
| 132799 |
Ok, here I confess I have friends with real equipment. The guy that gave me the aluminum does $1 million a year in government work! I went to another friend's race shop to use the shear and brake and made these bends. You CAN do it with a jigsaw and 2x4s to bend, but the right tools make it a lot easier. |
| 132095 |
I hit the aluminum with Harry's Makita Palm Sander and some 120 grit just to smooth things out. |
| 78621 |
Well the downside of using a shear and brake is that I couldn't do the tab in one piece. So I had to TIG weld in the tab. If you use a jigsaw and hand bend, you can just bend this tab to the 90 degree angle. |
| 92023 |
Here you can see measurement for the holes to drill. GO SLOW. |
| 101653 |
I used two thicknesses of Thermo Tape to isolate the shield from the proportioning valve bracket. No need to conduct heat here! |
| 96945 |
Another shot of the bent and welded shield. The first hole is from the template. The other two not yet drilled are marked in place. |
| 124757 |
Two holes drilled and fit, the third (top) is being marked. |
| 130026 |
All three holes done! At this point I fitted it and drove around. The master cylinder is SIGNIFICANTLY cooler. |
| 68715 |
Makita Palm Sander 120, 220, 320, 600, 1000, 2000 grit. It's not necessary but I then hit it on my buffer with some rouge. You can substitute Simichrome and some real elbow grease. Final polish is with Aluma-1...amazing stuff, though a bit hard to find. Total time is about an hour. |
| 154087 |
Looks good, fits well, and no I won't make you one! ;-P |
| 140810 |
Wow, you can see the turbo downpipe like in a mirror. Good thing I ceramic coated all that stuff so it doesn't reflect a rusty pipe! |