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Old 10-17-2007, 12:39 AM   #1
StretchSTI
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Default How To: DIY Radiator Cooling Panel

I got bored the other day and started to make a template for a cooling panel and it turned into a nice little project so i thought i would do a little DIY

Parts:
-Poster Board
-Sheet Metal

Tools:
-10mm and 12mm Socket
-Screwdriver
-Scissors
-Pencil
-Ruler or Straight Edge
-Dremel w/ cutoff wheel and grinder
-Drill w/ bits
-Hammer (optional)

Time:
-1.5-3 Hours

Heres what you start with


First, start by taking the Intake ram, Radiator mounts

Take the pop rivets out by first popping the head up and then grab the base and lift up. should come out easy.





Then make a template
-Cut out the general shape
-then go through and cut out the areas for the screws and radiator mounts.
-Lot of trial and error in this step




Once you have a template, Transfer it to a piece of sheet metal and cut the metal
-Mines a little thick, it doesnt need to be very thick


After you have your panel cut you can start to test fit
-grind with the dremel if you need to open your hole some.
-Bend the front a little to match the contours of the bumper

Once you are satisfied with the panel you can paint it or clear coat it to keep it from rusting

Heres my end result compared to my template.


Insert the pop rivets. push on the base to get it in the hole, then pop the head down


Install radiator mounts and intake ram


Here it is on the car
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Last edited by StretchSTI; 10-27-2007 at 01:30 AM.
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Old 10-17-2007, 12:43 AM   #2
Pssshhhhh!
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Nice job!
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Old 10-17-2007, 12:45 AM   #3
StretchSTI
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thanks... ill have it clear coated and final install tomorrow... will have better non- dead of night pics...
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Old 10-17-2007, 12:47 AM   #4
Dforce
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Where did you buy the sheet metal? and how much?
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Old 10-17-2007, 12:53 AM   #5
SIBzzz
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o man i was lookin for one of these. Great job bro
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Old 10-17-2007, 02:03 AM   #6
Remnex
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Nicely done my good sir.
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Old 10-17-2007, 08:48 AM   #7
Schnitz
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Looks great! Can you put the template into a PDF file so we can use it too?
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Old 10-17-2007, 09:01 AM   #8
bthomas
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Quote:
Originally Posted by Schnitz View Post
Looks great! Can you put the template into a PDF file so we can use it too?
Great idea. Great job. DIY FTW
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Old 10-17-2007, 09:01 AM   #9
YCT
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^^ word, you did all the measuring for us, might as well share it hehe
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Old 10-17-2007, 11:47 AM   #10
STiShawn
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I was just thinking that as well!
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Old 10-17-2007, 11:50 AM   #11
Uber Wagon
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I did the same thing a while ago. Mine looks almost identical. Great job!
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Old 10-17-2007, 12:15 PM   #12
PSI_XTC
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Hellooo project for this weekend.
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Old 10-17-2007, 12:28 PM   #13
StretchSTI
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You lazy bastards... haha i would ask the same thing.
when i got some time ill do all the measurements and lay it out on the computer.

Quote:
Originally Posted by YCT View Post
^^ word, you did all the measuring for us, might as well share it hehe
there wasnt too much measuring... more of just a trial and error deal with the template. ill make a more legit template on the computer for you guys when i get time.

Quote:
Originally Posted by Dforce View Post
Where did you buy the sheet metal? and how much?
i went to a friend of mine that is a fabricator and had him cut out the general shape for me, not the cheapest idea. there is a metal yard right down the street from me im sure would have what is needed. you can also just try to find something at home depot or an auto parts store that would work.

Thanks for all the good words!
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Old 10-17-2007, 01:10 PM   #14
STiShawn
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I was thinking of roof flashing, thin guage comes in a roll for pretty cheap, easy to work with
I also have a roll of mudflap material I was looking at, not the rubber but the poly
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Old 10-17-2007, 01:31 PM   #15
xdrian
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how thick is that aluminum ?
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Old 10-17-2007, 02:15 PM   #16
lokies
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thats awesome....i'm assuming its the same for 04-05s....
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Old 10-17-2007, 02:18 PM   #17
o2sys
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wow thats pretty good, better than most cooling JDM panels i've seen...
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Old 10-17-2007, 02:36 PM   #18
StretchSTI
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Default

Quote:
Originally Posted by STiShawn View Post
I was thinking of roof flashing, thin guage comes in a roll for pretty cheap, easy to work with
I also have a roll of mudflap material I was looking at, not the rubber but the poly
I was thinking of flashing too when i typing the post about going to home depot... not to sure on it, might try it.

Quote:
Originally Posted by xdrian View Post
how thick is that aluminum ?
Too thick. he said it was 8 thousandths or something. go with something much thinner.

Quote:
Originally Posted by lokies View Post
thats awesome....i'm assuming its the same for 04-05s....
Im not sure... never really payed attention to the Radiator support on 04-05's

Quote:
Originally Posted by o2sys View Post
wow thats pretty good, better than most cooling JDM panels i've seen...
Thanks
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Old 10-17-2007, 02:42 PM   #19
STiShawn
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Default

The flashin may work, whats the rough rectangular dimensions on it (ie Length width)
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Old 10-17-2007, 02:46 PM   #20
WRXLTD
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If you could make those for $25 or less a piece and put it up on eBay, I'd bet you'd make some money on that bad boy.

Good job.
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Old 10-17-2007, 06:19 PM   #21
I Love Boobies
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when you post final pictures, can u also show what it looked like stock?
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Old 10-27-2007, 01:31 AM   #22
StretchSTI
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Default

updated the post

heres a pic of the general dimensions. they may be off, i dont know. i did the template completely from trial and error so the measurements are rough.



**NOTE: the cut out for the latch has a 3/4" dia.
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Old 10-27-2007, 12:00 PM   #23
STiShawn
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I made mine last weekend out of some spare sheet poly I had...too bad it was purple.
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Old 10-28-2007, 12:42 AM   #24
StretchSTI
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take it out and paint it... the purple does look a little outta place
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Old 10-29-2007, 03:11 PM   #25
BeBop86
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Does this really have a significant benefit? or is it just in theory?
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