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You will need..
A drill,
A drill bit,
A grinder,
Eye protection glasses/goggles,
Leather garden gloves,
10 mm 1/4 socket,
1/4 drive ratchet and extension piece
Sheet of steel to choice,
Ruler/Measure,
Marker pen,
Metal file,
Bit of IPA or similar... marker remover fluid/wipes,
A grid or gate ?....
We will assume that you have already fitted you induction air filter kit?...remove the 2 x 10mm head bolts that hold the OE air box bottom bracket in place using the 1/4 ratchet,extension and 10mm socket, we will need the 10mm head bolts so put them somewhere safe for the minute.
So to the sheet we will be using for this....
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And then you need to mark out the measurements for the bends, cuts and drill points....
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Which are...
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****PLEASE WEAR EYE PROTECTION......YOU ONLY GET ONE SET OF EYES, AND ALSO DON'T FORGET GLOVES BECAUSE OFF SHARP EDGES FROM CUTTING****
Grinder out and cut it out, you can use tin snips but will take some time and distort the edges, personally I like to round the corners off and don't forget to file those sharp edges off....(yes I know I have no gloves on, but eye protection was)
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And then round off the edges and clean up the cut lines...
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And then it is time to bend it into shape , as long as you have the correct lines bent you can finish fettling into the correct shape/position once fitted...
So over to the bending machine....gate or grid ....
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Lets bend....
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Then to the next line and so on.....
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Once bent to your choice using your method of attack.....
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Now drill the two fixing holes once bent into shape with a drill bit making two drill holes in each mark, I am using a step down drill bit, but a Dremel will be ideal for this.....
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Get some snips and cut the middle of the 4 drill holes.....
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Once cut, get a file to file flat, Dremel metal grinder bit works best, don't forget to de-burr the drill holes etc..
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Clean all the measurements marks off....
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And then it is ready to fit, after you have painted it, polished it...
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As you can see from the pictures of this one we extended it and lengthened it (pics are of a M1 1.6 but will fit all 1.6/1.8 to 2005)...
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So save yourself some cash and go make your own .....
As always any questions, please just ask......it's what we are here for.
M-m
