AudiForums.com - Intake Heat Shield DIY

This heat shield is designed to keep the extremely hot air in the engine bay away from the open air intake many of us have added to our cars. It can also be used with the stock air box, if you can find a way to make it fit. Please keep in mind this is made for a 1996 A4q 2.8. It should work for any audi as long as you follow the directions correctly.

DISCLAIMER: This is soley to help other audi enthusiasts to help control the air temperature going into their engine. I am not responsible for any damages or alterations to your vehicle. Cutting aluminum can be very sharp and dangerous. Please be careful.

Ok now that that is out of the way here we go.....

Materials:
1 roll of aluminum = $10
1 roll of furnace fiberglass insulation = $10
1 roll of foil tape = $5
1 door weather strip = $5
metal epoxy = $3
cardboard 2'x2'
http://i15.tinypic.com/2wfiznr.jpg

Begin by removing the Filter, MAF, and rubber tubing connecting it to the Throttle body. Basically loosen the clamp as shown, and gently remove the metal clasp holding the wiring to the MAF.
http://i15.tinypic.com/48guofq.jpg

Also remove the two screws holding the plastic piece that routes air to the air box from the front of the car, and remove that piece.

Once everything is out of there its time to create your template. Take your time by cutting the piece of cardboard until if fits perfectly next to the engine block. Make sure it comes up high enough to where it will barely fit when the hood is closed (almost touching). Be sure to also cut out a notch that will accomodate the tubing, air filter, and misc. wires near the back of the engine block. Unfortunately I did not take a picture of my template so I applogize for that. Take your time because thisis the most important step.

Cut a piece of the aluminum sheet large enought to fit your template on. Make sure to leave at least 2 inches on the bottom of the template ( I'll get into this later). Carefully trace your template on the sheet and dont forget to leave some room at the bottom.
http://i15.tinypic.com/30voswh.jpg

Now cut your piece of aluminum like a big kid right around the outline. I also put a dashed line on the bottom of my template to note where it actually ended, you will see this in the next picture. Fold your newly cut piece at that line, this will help the shield structurally and prevent it from bending. Fold it towards the intake side of the engine if the shield were in the car as it will be. Also cut out a piece large enought to easily put the air vent from the front of the car through the shield...
http://i15.tinypic.com/2lkuyz9.jpg

At this point I added a little more strucural support. You can skip this step but I highley recommend it. I cut another piece of aluminum about 9"x3" fold this into thirds making a triangular tube. This will be attached using the metal epoxy to the intake side of the shield. Look at the picture for this because I cant really explain it too well.
http://i9.tinypic.com/4igmwxf.jpg

Allow that to dry, the epoxy I used was done in about a half hour. Now flip the shield over so you have the flat, engine side facing up. Cut a piece of the fiberglass insulation large enought to cover all of the aluminum. place it on top with the fiberglass side on the bottom. Cut it to the appropriate size remembering to cut a piece out where the hole you made is.
http://i7.tinypic.com/2m6jpg8.jpg

Tape all the sides with your foil tape. I also taped around the opening I made just to get the sharp edges taken care of.
http://i9.tinypic.com/29mkbkj.jpg

Cut the weather stip to the correct length to go across the top of the shield. Attach to the intake side. It comes with self adhesive sponge tape, but I would also add some more foil tape to make sure it is secure. This will help seal the intake side of the shield from the engine block side when the hood is closed.

http://i18.tinypic.com/3zhjj1t.jpg

Place the shield in the engine and hook up the MAF, Filter, and tubing. Re-connect the wires to the MAF and dont forget to put the metal clip back on.
http://i7.tinypic.com/2afebdk.jpg

Carefully route the air vent through the hole you made and you're done! This has done wonders for keeping my intake cold, and hopefully it will help you. Remember to take your time especially when making your template...

http://i15.tinypic.com/42kqq8y.jpg
http://i5.tinypic.com/3482fx0.jpg