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markbrotens 07-04-2008 03:36 AM

Walk-through: Intercooler Screen
15 Attachment(s)
This is my first walkthrough so hopefully it is easy to follow.

I wanted to make something to stop those pebbles from denting the fins on the intercooler and something to catch the bugs and leaves. I also wanted it to match the open induction cover that I had previously made.
Attachment 54703

For some reason I am not able to zoom in on the images by clicking on them, but if you right-click and go to "open in a new window" or "tab" they will work. If you are running firefox, clicking on the image with the center mouse button will open the image in a new tab.


-1/16" x 3/4" x 4 foot aluminum angle
Attachment 54705

-a screen of choice at least 9"x10" (I found a 3'x9' sheet of it at Home Depot for $12 and plan to use it for projects to come)
Attachment 54706

-16 machine screws and nuts - I used 8-32 x 3/8"
Attachment 54707

-8 washers to put between the screen and the nuts - I just used what was lying around.

-1" (or whatever you want) corner braces
Attachment 54708

Tools required:

-framing square (or triangular template)
-sander (or if you have the time and patience, a file)
-wire cutters
-drill and bit to match machine screws
-bench vise would be handy

Step 1: Making the the aluminum angles.

Starting at one end, use the framing square to mark a 45 degree angle on one side and a strait (90 degree) mark on the other.
Attachment 54709

With the lines marked, clamp the aluminum in the vise and use the hacksaw to cut just outside the lines.
Attachment 54710

Using a sander (or file) sand it down the the marked lines. I used a bench belt and disc sander.
Attachment 54711

Once you get the angle right (45 degrees), measure and mark the other end of the first piece at 10 1/4", then cut and sand down that end.

Repeat the above process for the other 3 pieces. You may want to measure you intercooler to decide how you want tight you want it to fit. The dimensions of mine was 10 1/4" x 9 1/4". Therefore two 10 1/4" pieces and two 9 1/4" pieces will be needed.

Once all 4 pieces are done, lay them face down on a flat surface and see how accurate the corners are. As you can see the the picture below, when the corner is tight, the angle is a bit off, so it's back to the sander.
Attachment 54712
Attachment 54713

Step 2: Putting together the frame

Once it all lines up, it's time to attach them to each other.

Put the corner braces in place and mark the holes with a marker. Make sure the the angle between the aluminum is tight.
Attachment 54714
Attachment 54715

I would recommend using a punch to create a center for the drill bit to follow. Even with the punch, the bit tends to wander due to the softness of the aluminum.
Attachment 54716

Once the holes are drilled, attach the bracket and tighten it so that the remaining corners will be easier to line up.
Attachment 54717

I would recommend checking the fit on your intercooler along the way, just in case you have to trim any pieces.

Here is the fit of mine after putting it together.
Attachment 54718

markbrotens 07-04-2008 03:46 AM

9 Attachment(s)
Step 3: Cutting and attaching the screen

Now measure and cut a piece of screen large enough to cover the frame and then trim it with wire cutters to fit inside.
Attachment 54719

Now drill 2 holes on each side of the frame to attach the screen to the frame. Spacing is up to you, but try to keep it even because the tops of the machine screws will be visible.
Unfortunately I got caught up in my work and forgot to take pictures of these steps.

Use machine screws with washers and nuts to attach the screen to the frame.
Attachment 54720
Attachment 54721

Now the screen is done!:)

Step 4: Fitting the engine cover

If you don't have an engine cover, this obviously won't apply to you. If you do, use this part of the walkthrough as a very loose guide.
I had to modify the engine cover to fit over the screen, but depending on how you did yours, you may only need to modify yours a bit or even not at all.

Basically, I had to trim the plastic parts that used to come into contact with the intercooler so that they now come into contact with the screen. It's hard to get a picture of what I did, but here is where I trimmed it down.
Attachment 54722
Attachment 54723
Attachment 54724

A dremel would be the best tool for this, I don't have one so I used a combination between a jigsaw, a file, and a sander.

Use your best judgment on how much to take off, checking it many times in between.

Your Done!:) I hope you had as much fun with it as I did!


Attachment 54725
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Attachment 54727

Darkness of Death 07-04-2008 05:06 AM

looks good - though it should be in the walkthroughs section ~

markbrotens 07-04-2008 11:45 AM

Yeah, I wasn't sure where to put it, maybe a mod can move it

Infamous1 07-04-2008 11:46 AM

Agreed move to walkthroughs section.....

Nice Work!

markbrotens 07-04-2008 02:36 PM

For some reason I can't zoom in on the pictures now, can anyone else? How would I change that?

Infamous1 07-04-2008 02:42 PM

Works fine for me...

Mark34 07-08-2008 02:06 PM

1 Attachment(s)
Ok, not to thread jack, but what did you do to your air intake filter? Same kind of screen casing like your IC screen? Looks like a custom filter and heat shield. Can't say I've ever seen a set up like that set up before...

markbrotens 07-08-2008 02:48 PM

1 Attachment(s)
Yeah, I made the Open Induction Cover a couple of weeks before the Intercooler Screen. It is essentially made the same as the IC screen, just a different size and a couple of mounting brackets to hold the intake in place. The heat shield is lexan or duraplex or something like that which I purchased from Home Depot. It works really well - there is a huge temp difference on either side. I normally have the air intake scoop on to supply constant cold air to the area.

ppettit2005 12-20-2009 08:07 AM

dude, I wish I had done this to mine instead of the way I mounted mine.

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