Interior/Exterior Yet Another DIY Intercooler Screen
#1
Yet Another DIY Intercooler Screen
Sufficiently inspired by getata and Ian G's "MCS Intake/Intercooler/Mail Slot/Grill Screen" mod pics and how-to's (and many other "mentions"), I took advantage of an off-day and tried it myself.
I've posted this write up along with "lessons learned" for future modders...
DIY MCS Intercooler/Hood Scoop /Air Intake Grill Screen
Difficulty Rating: Easy
Est. Cost: $3.00
Est. Time: 1 hour
Supplies & Tools Needed:
Gutter Guard Screen or Vent Screen (15"x 3" or more*)
Tape Measure
Pliers (or 8mm socket)
Phillips screwdriver
Wire cutters or "snips"
[fig 01]
1. I went to the local Home Depot just to find they stopped carrying the gutter guard screens! Ack! I improvised and picked up a 16"x6" vent screen from the Heating & Air section, (which actually nets 14.5" x 4.5" of useable screen material). Note: the hood scoop hole is 14.75" x 1.75", so you know what that means!*...
[fig 02]
2. I removed the (black, plastic) interior of the hood scoop from under the hood. My 06 MCS only had two (8mm) nuts to remove, and two screws...
[fig 03]
In these pics you can see what the hood/hood scoop looks like w/o the interior piece...
[fig. 04, 05]
3. I carefully began snipping the wire mesh from the vent frame. This took about 10-15 minutes. If you can find the gutter guard material you won't have to do this step. If you have to do this step, just be patient and snip carefully...
[fig. 06,07]
4. I didn't make a template like I've read, but chose to "eyeball it" by laying the wire mesh on top of the scoop. I aligned the bottom of the wire mesh onto the bottom ridge, and marked along the upper ridge with a red whiteboard marker (which should wash off eventuall)...
In these pics you can see the "ridge" the screen must fit into...
[fig. 08, 09]
[fig. 10,11]
5. I proceeded to cut out the screen accordingly. It's better to cut on the outside of the marking than on the inside, because you can always trim down later...
[fig. 12,13]
6. In this pic you can see that the screen is slightly larger than the scoop hole, which worked out to my advantage- Since the screen is so flexible I was able to pop it in without it falling out. Now to see how it fits!...
[fig. 14]
7. I put the plastic hood scoop interior back into place but didn't tighten all the screws. Here you can (sort of) see where the top center doesn't fit securely because this is where a piece of the exterior scoop wants to snap into the interior. I removed the plastic hood scoop interior and screen, eyeballed the change, and trimmed this little piece out...
[fig 15]
8. I put everything back together w/ the screen sandwiched between the exterior and interior scoop pieces. Result, yet another DIY Intake screen!
[fig. 16,17]
*From the last two photos you'll see that the screen is actually a smidge too small! Doh! For $2.49+tax, this works for now. I may decide to paint it black to make it less noticeable, or try again with some better material.
What would I do differently?
1. I would measure the intake hole before going shopping!
2. I would make a template and upload it for anyone to use
3. I would probably shop around for better material (I'd love to get my hands on a spare mesh (plastic) radiator grill (hint, hint)...
Overall, not a bad day!
This project inspired by:
getata (https://www.northamericanmotoring.co...ad.php?t=73812)
Ian G (http://www.tech-esq.com/MINI/how_to_...oop_grille.htm)
and
Blair of West Coast MINIs, who emailed me a written step-by-step (no pics) of his project and encouraged me to try it myself!
**This write-up and full size photos available at: http://bushfingermini.blogspot.com/2...oop-grill.html
getata (https://www.northamericanmotoring.co...ad.php?t=73812)
Ian G (http://www.tech-esq.com/MINI/how_to_...oop_grille.htm)
and
Blair of West Coast MINIs, who emailed me a written step-by-step (no pics) of his project and encouraged me to try it myself!
**This write-up and full size photos available at: http://bushfingermini.blogspot.com/2...oop-grill.html
Last edited by irieman; 07-26-2006 at 11:35 AM. Reason: fixed broken images and typos (go figure)...
#4
#6
Originally Posted by Turcicus
Awesome DIY! I just picked up my MCS today, and plan on doing this sweet little mod sometime this week. It's great to see some pics of everthing before I jump in.
This may be the easiest "homegrown" mod I've run across (as oppossed to buying things and bolting them on- which I'm pretty good at *wink*).
]i[
#7
I've got a line on some better aluminum billet for these peices, based on a 15" x 2" measurement above (which will give a bit of wiggle room beyond the size of the intake hole)... I've seen several hole patterns with about 52% open space, give or take. I'll let people know what I find, price wise... most of the places I'm finding seem to deal in pretty large quantities and may have a minimum ammount for orders. If so I MAY get the larger peice and then cut down smaller units for my use and possibly re-sel to others (shrug).
A printable template would be awesome, I agree, but the 15" length will mean that most printers cannot handle it, remember. I'd do it as HALF the length and give instructions to cut out two of them, then tape together at the center.
A printable template would be awesome, I agree, but the 15" length will mean that most printers cannot handle it, remember. I'd do it as HALF the length and give instructions to cut out two of them, then tape together at the center.
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#8
Originally Posted by iriemanhq
Oooh another newborn MCS! (pics? hint!). Mine is officially 1-1/2 weeks old! Glad this write up might help folks out- as noted, it's not the only one out there...
This may be the easiest "homegrown" mod I've run across (as oppossed to buying things and bolting them on- which I'm pretty good at *wink*).
]i[
This may be the easiest "homegrown" mod I've run across (as oppossed to buying things and bolting them on- which I'm pretty good at *wink*).
]i[
#10
Originally Posted by kenchan
that looks pretty good! i think im going to stop by the hardware store tomorrow.
Would Ace Hardware have those galvanized white gutter mesh?
Would Ace Hardware have those galvanized white gutter mesh?
#11
Originally Posted by Turcicus
Did you still want a white one out of the gutter guard? I haven't forgotten about you (from the other scoop screen thread), I just haven't had a chance to make mine yet.
they have the gutter guards there. i also made sure i got the horizontally
wide ones, not the verticle so that it matches the honeycomb on the
aero grill. im not sure if mine's galvanized, but it doens't smell like
bare tin (nor do my hands), so i think it is. Atleast it looks painted.
will put this thing together tonight.
btw, $2.82 with tax!
#12
Originally Posted by kenchan
doh! i just got back from AceHarware. thanks anyways.
they have the gutter guards there. i also made sure i got the horizontally
wide ones, not the verticle so that it matches the honeycomb on the
aero grill. im not sure if mine's galvanized, but it doens't smell like
bare tin (nor do my hands), so i think it is. Atleast it looks painted.
will put this thing together tonight.
btw, $2.82 with tax!
they have the gutter guards there. i also made sure i got the horizontally
wide ones, not the verticle so that it matches the honeycomb on the
aero grill. im not sure if mine's galvanized, but it doens't smell like
bare tin (nor do my hands), so i think it is. Atleast it looks painted.
will put this thing together tonight.
btw, $2.82 with tax!
#14
#15
I may be on to some really nice drilled steel or something similar for this mod... Keep your eyes on this space for more details soon, I hope. No promises, but for now, since this MOD is practically free except for your cuting and installation time, you might as well go Gutter Guard until I find out more.
That looks tough, Kenchan- nice work! Did you cut after using a template or did you eyeball it?
That looks tough, Kenchan- nice work! Did you cut after using a template or did you eyeball it?
#19
Originally Posted by Turcicus
kenchan, good stuff. I did mine last night as well, but finished in the dark, so no pics yet. I'll get some up tonight. And I agree, the cutting is a PITA...
thanks. cool, looking forward to your picts.
yep, i started with wire cutters but the cut clarity(?) was not precise
enough to my preference so used sheet metal scissors and that got it
to the level of craftsmanship i could accept. but i must've
poked my hand like 10x... ouch.
so no one wants these, huh? oh well. i guess i'll paint them and hand
them out during local meets... get a free intercooler grill with ken's
PDR service! lol... installation extra. wink wink
#22
#23
Originally Posted by welshmenwillnotyield
Kenchan, I'd like one in red, if they are being offered in colors.
Jeff
Jeff
3 silvers left. sticks to magnet, so these are galvanized steel.
1. ImagoX - black (pending)
2. welshmenwillnotyield - black (confirmed)
3. shukes24 - black (confirmed)
4.
5.
6.