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#1: 07-04-2008, 03:36 AM
Walk-through: Intercooler Screen
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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.
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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
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-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)
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-16 machine screws and nuts - I used 8-32 x 3/8"
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-8 washers to put between the screen and the nuts - I just used what was lying around.

-1" (or whatever you want) corner braces
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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.
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With the lines marked, clamp the aluminum in the vise and use the hacksaw to cut just outside the lines.
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Using a sander (or file) sand it down the the marked lines. I used a bench belt and disc sander.
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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.
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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.
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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.
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Once the holes are drilled, attach the bracket and tighten it so that the remaining corners will be easier to line up.
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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.
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Last edited by markbrotens; 07-04-2008 at 02:45 PM..
The Following 2 Users Say Thank You to markbrotens For This Useful Post:
chimera (05-02-2013), techs21 (03-23-2012)
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