Intake heat shield template

[Jake_rorx7]

I've just bought part of a petit intake system to replace my ARC box (will be for sale when I've swapped it if anyone is interested..). I have found a intake shield diagram/template to use and modify with some carboard designed aluminium here:

http://www.myrx7.com/images/damians_intake_heat_sheild_template.pdf

Does anyone have any links or photos of other templates to share that I can use and modify? Also yes I know I can buy the proper petit shield from their site but I dont feel like paying £54 SHIPPING for metal sheet.

Otherwise, when I'm done with this shield and modified it further, I will reupload a template for others to use.

 

[initialDean]

Whats it look like? I'm in the process of designing a cooling panel for my car at the moment I have a laser to cut ali and steel

 

[Jake_rorx7]

Whats it look like? I'm in the process of designing a cooling panel for my car at the moment I have a laser to cut ali and steel

Here is the thread I got the template from which contains some info: https://www.rx7club.com/3rd-generat...pics-custom-intake-damian-heat-shield-285483/

And the petit shield looks like this (I believe this is a view from the intercooler side of the shield, left is toward the front of the vehicle):

Basically just something to seperate the hot radiator air from the cool air that passes around the radiator. Its only 2 inches wide, but should be plenty for keeping a fresh supply of air when the vehicle is moving. Ideally, I'm going to focus on getting it to seal well to the bonnet and radiator (with the help of some foam), then go as far back toward the manifold as possible to prevent the hot air mixing when the car is stopped. If I want to be fancy, I might even make something for the back side of the filters to seperate from turbo heat, but that shouldnt matter unless youre stopped. The damian design accomdates the air pump, which I dont have (hence the need to modify and extend the shield).

 

[Jake_rorx7]

Whats it look like? I'm in the process of designing a cooling panel for my car at the moment I have a laser to cut ali and steel

Also what does your cooling panel do?

 

[rx_dreamer]

Whats it look like? I'm in the process of designing a cooling panel for my car at the moment I have a laser to cut ali and steel

handy tool to have!

 

[initialDean]

Also what does your cooling panel do?

not sure! LOL just tidies it up and helps keep the air coming in pointing at the right places

 

[Jake_rorx7]

not sure! LOL just tidies it up and helps keep the air coming in pointing at the right places

Nice, the air is gonna be so CRISP from all this cut metal in the engine bay haha!

I'm also designing a duct for a greddy smic, currently got version2 in carboard ready to test fit this weekend! Cant stand high intake air temps. Last step is going to be installing a water mister into the IC ducting and a fan on the back of the IC. Won't rest until my intake temps equal the ambient air temps..

 

[initialDean]

have you got a fast acting intake sensor? I fitted one last week. makes a difference. Temps go up faster but fall faster too

Sounds like you are planning the same stuff I am

 

[Jake_rorx7]

have you got a fast acting intake sensor? I fitted one last week. makes a difference. Temps go up faster but fall faster too

Sounds like you are planning the same stuff I am

I think so - I gave one to Stu when it was rebuilt and didnt get it back, so I'm happy to assume its in. I have access to professional motorsports temperature probes, so when I'm happy with my modifications I'll stick some in various locations and log the temperatures on a drive. I have a feeling the problem with the onboard temperature sensor is that the actual sensor heat soaks, so it will be interesting to see the difference between the on-board reading and my measured temperatures.

As far as the on board temp sensor says, I started with 55-70 degrees intake temps before the rebuild, and with my current setup I usually run 20-30 degrees over ambient (crusing), but its still nowhere near enough. Especially the heatsoak when stationary is terrible, I can see 50-60c temps if I wait at traffic lights for a few minutes, and if I pop inside a shop for 20mins then that means no more boost for the next 10 mins driving.

 

[rx_dreamer]

get a humongous V mount

 

[Jake_rorx7]

get a humongous V mount

I would if I wasn't a cheapskate!!

In all seriousness... I'm saving for a house deposit, and really need to save money where I can so that I dont have to sell my 7 or my mx5 tbh I enjoy little projects like this ducting, so I really don't mind putting in the labour to make something decent and keep me occupied.

 

[rx_dreamer]

LOL love it, house deposits are an FDs best friend!

Go easy on the loud pedal

 

[MILLION]

 

[initialDean]

I think so - I gave one to Stu when it was rebuilt and didnt get it back, so I'm happy to assume its in. I have access to professional motorsports temperature probes, so when I'm happy with my modifications I'll stick some in various locations and log the temperatures on a drive. I have a feeling the problem with the onboard temperature sensor is that the actual sensor heat soaks, so it will be interesting to see the difference between the on-board reading and my measured temperatures.

As far as the on board temp sensor says, I started with 55-70 degrees intake temps before the rebuild, and with my current setup I usually run 20-30 degrees over ambient (crusing), but its still nowhere near enough. Especially the heatsoak when stationary is terrible, I can see 50-60c temps if I wait at traffic lights for a few minutes, and if I pop inside a shop for 20mins then that means no more boost for the next 10 mins driving.

mines much the same... normal running will see them hover around 30... but as soon as i floor it. they will go to 50+ so have to keep my eyes on it

 

[Jake_rorx7]

Okay template is ready to go.. will test fit (along with my greddy ic duct) at the weekend and see where we can add material or alter the shape. Mainly concerned with sealing the top piece against the radiator/bonnet/front brace/engine block. As long as it's within ~2cm we can use edge trim to seal fully.

I'm thinking of getting some aliminized (?) Fibreglass adhesive sheet to increase the thermal barrier the aluminium will provide, and stop the alu shield from heating up, then heating the air on the intake side. The same for the IC duct. Ideally this would be zircocoated, but that's expensive.

 

[rx_dreamer]

Everyone on this forum has fancy mats and mice !

 

[Jake_rorx7]

Everyone on this forum has fancy mats and mice !

Lol, to be honest I was just trying not to get my crotch in the photo lmao

 

[Jake_rorx7]

I've never seen a good set of photos online regarding this intake so here you go

Some things I've learned - the shield is only really secured through one bolt hole which attaches to the stock box bolt location near the intercooler, but this does seem to have issues touching the greddy. Also the mount can't be bolted in the normal place because the greddy is occupying the bolt hole. This can be resolved by shortening this mount arm (on the shield) by an inch ish, and moving the support arm one bolt hole to the left.

I did have to remove the front flap which would extend in front of the radiator - it blocked proper fitment and also would only serve to block airflow to the intake from the bumper.

This has a snug fit against the fuse box which I believe could be improved by removing some shield material and including a rubber seal around the edge.

The notch on the top is for the bonnet prop - if you have struts you can eliminate this.

The shield can be extended to the rear for those of us with a air pump delete by up to 20cm. The only thing that would really get in the way is the lower intake hose

The notch on the lower portion for the overflow hose had to be deepend by about an inch because I didn't have enough free overflow hose due to my ast placement. You can eliminate this notch if you have enough or no coolant hose here.

 

[Jake_rorx7]

More photos..

 

[Jake_rorx7]

Peep the noodle legs... My changes (improvements? Hopefully) to the base sheet. Drawing onto aluminium sheet as we speak.

Removed bulge at the bottom so it's flush with the radiator and does not impede flow

Deepend the coolant overflow notch

Shortened the top piece at the front by 10mm (20mm rubber trim will make a better deal)

All lines areas are where edge trim is needed, either basic trim to stop cutting/vibration, or 20mm rubber seal trim to seal airflow.