I finally completed the project to box my radiator and heat exchanger. I suspect there is a better way of doing this, but it worked well for me and I think it's going to last a long time.
This was not a difficult project, but it was EXTREMELY time consuming. You have to measure, cut, mock-up, cut more, mock-up, find holes, etc etc. You find yourself making very small changes at a time to be careful and taking things apart and putting back together continuously to get a good fit.
I used normal home tools, like a drill, vice, hammer, pliers, tin snips, wrenches, utility knife, hand rivet gun, and screwdrivers. A sheet metal brake would make it easier, but if you're patient with 2x4's and a hammer, you can get it done.
Supplies included 0.025" thick aluminum sheet metal from a hardware store, lots of #10-24 x 3/4" screws, wing nuts, washers, 1/8" aluminum rivets, small diameter vacuum hose (to protect the intercooler lines from the sharp edges), lots of cardboard, and 1/4" body panel plastic push pins (like used at the factory).
First, cut pieces of cardboard to approximate each of the panels. When you cut the cardboard, keep in mind that the sheet metal will be much stiffer and be sure to mark where you want attachment tabs. If you forget the tabs, you'll be throwing away your first set of cut sheet metal!
I ended up making 6 panels of sheet metal; 2 for each side (riveted together to create 1 panel per side) and 2 for the bottom (screwed together and also screwed to the bottoms of the side panels).
Rather than mocking up everything at once, work on one side, make/install the sheet metal, then move to the next side and repeat, then finally move to the bottom. You'll learn as you go, so you want to get each side done individually before repeating mistakes elsewhere.
Here is the top half of the right side.
Here is the bottom half of the right side. I didn't get a pic of the other side, but it's similar without the intercooler holes.
Here is the top half of the left side.
Here are the two pieces for the bottom. Left is front and right is rear. Notice all of the holes for attachment points! Each one has to be very carefully located.
Here is a shot from the bottom.
This was not a difficult project, but it was EXTREMELY time consuming. You have to measure, cut, mock-up, cut more, mock-up, find holes, etc etc. You find yourself making very small changes at a time to be careful and taking things apart and putting back together continuously to get a good fit.
I used normal home tools, like a drill, vice, hammer, pliers, tin snips, wrenches, utility knife, hand rivet gun, and screwdrivers. A sheet metal brake would make it easier, but if you're patient with 2x4's and a hammer, you can get it done.
Supplies included 0.025" thick aluminum sheet metal from a hardware store, lots of #10-24 x 3/4" screws, wing nuts, washers, 1/8" aluminum rivets, small diameter vacuum hose (to protect the intercooler lines from the sharp edges), lots of cardboard, and 1/4" body panel plastic push pins (like used at the factory).
First, cut pieces of cardboard to approximate each of the panels. When you cut the cardboard, keep in mind that the sheet metal will be much stiffer and be sure to mark where you want attachment tabs. If you forget the tabs, you'll be throwing away your first set of cut sheet metal!
I ended up making 6 panels of sheet metal; 2 for each side (riveted together to create 1 panel per side) and 2 for the bottom (screwed together and also screwed to the bottoms of the side panels).
Rather than mocking up everything at once, work on one side, make/install the sheet metal, then move to the next side and repeat, then finally move to the bottom. You'll learn as you go, so you want to get each side done individually before repeating mistakes elsewhere.
Here is the top half of the right side.
Here is the bottom half of the right side. I didn't get a pic of the other side, but it's similar without the intercooler holes.
Here is the top half of the left side.
Here are the two pieces for the bottom. Left is front and right is rear. Notice all of the holes for attachment points! Each one has to be very carefully located.
Here is a shot from the bottom.
Like I told Jimmy above, I'm happy to share whatever I have to help others. If it would help, I could post where each of the holes in the bottom plate attaches.
