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.
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
-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)
-16 machine screws and nuts - I used 8-32 x 3/8"
-8 washers to put between the screen and the nuts - I just used what was lying around.
-1" (or whatever you want) corner braces
-framing square (or triangular template)
-sander (or if you have the time and patience, a file)
-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.
With the lines marked, clamp the aluminum in the vise and use the hacksaw to cut just outside the lines.
Using a sander (or file) sand it down the the marked lines. I used a bench belt and disc sander.
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.
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.
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.
Once the holes are drilled, attach the bracket and tighten it so that the remaining corners will be easier to line up.
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.