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Old 12-16-2014, 10:31 AM   #26
tedan628
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wow i need this now
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Old 12-22-2014, 06:19 PM   #27
whitefrs
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I need this box!!!!!!


Sent from my iPhone using NASIOC
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Old 12-30-2014, 10:28 AM   #28
goswald79
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This is a very nice build and write up. This is what I look for when I come to the fabrication section.

Kydex is a pretty awesome material. I was always curious why no one used it for automotive applications. It is fairly cheap, withstands continuous use, is easy to form, and well, pretty damn awesome! I have the Cobb box for my 2003, but I may be fabricating a replacement!
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Old 01-07-2015, 01:01 AM   #29
JaH13
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A very detail oriented write up and end product. Kydex belongs in an engine bay. Also after reading this post I did some searching and the stuff sounds like it could applicable to a lot of things.
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Old 02-10-2015, 03:38 PM   #30
Ronson
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i need a box...make me one ! lol ....but really anyone have one for sale ? i have the intake.
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Old 03-16-2015, 11:29 PM   #31
abnrdo
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You have given me a lot of ideas! Thanks!
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Old 06-23-2015, 03:19 PM   #32
Osgood30
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So being inspired by this thread and needing to get some heat barrier for my intake, I decided to buy all the same materials and make an air box / air shield for my filter. Given that my car is swapped 99 RS, its even harder to find something.

Decided on making just a shield, instead of full enclosed box due to some space constraints and other reasons. Due to different engine bay layout than the OP's 15 STI, my shield had to be made with angles other than 90 degrees. And as I was making it, I really began questioning if Kydex really does belong in the engine bay, as some of you asked. The reason I say that, is that while I was heating specific section to make a particular bend, it was hard to keep other section from warping due to them getting warm. It also seemed that the material would become pliable way to quickly. I wonder if engine bay temperatures would make it hot enough for it to start warping just a little. I am not saying that it will just melt into a puddle, but I dont know if it will be sufficiently rigid.

Here is some pictures of the shield in progress. I was still planning on adding the bottom piece






Here is what I had to do in order to bend it and have it keep its shape throughout the whole process.







So like I said, I am actually on the fence right now about whether or not I should finish it, or just make it out or a sheet of aluminum, then cover it with a sheet of heat wrap like OP did.

As you can also see in the GC8 body this is much closer to say turbo.

joejoe69, do you have any long term reviews of you intake?
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Old 06-23-2015, 04:00 PM   #33
joejoe69
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Nice work. Prior to purchasing and installing my Cobb SF airbox for the 15 STI, my 1/8" thick Kydex airbox held up the whole time since I installed it. However it did show slight warpage only at the section below where the silicone tube enters the airbox die to that area being closest to the engine. After that inital engine heat cycle, it permamently stayed that way. It would have been a different story if the DEI tunnel/shield heat barrier was outside instead of inside the box.

I have two sheets of 1/4" thick Kydex. I'm sure it will hold up better this time around as well as keep things cooler than the Cobb aluminum heatshield. Through my testing and observations, my 1/8" thick Kydex box performs much better than Cobb's. IATs read lower with Kydex.
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Old 06-24-2015, 08:21 AM   #34
Osgood30
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Thanks for chiming back in.

I think I am going to redo the shield out of 16 gauge aluminum. As much fun as it is to work with Kydex, I just don't like how close one edge its going to be to the turbo. Plus if I still apply that DEI tunnel sheet and that lava mat to the aluminum box, it should help that great deal.
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Old 07-29-2015, 03:25 AM   #35
joejoe69
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Default DIY Kydex 2.0 Airbox

Just a quick sharing of my Kydex v2.0 heatshield. Been busy for a while but I managed to sacrifice 8hrs to build this airbox/heatshield this past Saturday. It's made of 1/4" (nominal) Kydex T thermoplastic, which is 1/8" thicker, more durable, and much more heat resistant than my first Kydex V airbox. It conducts significantly less heat than any aluminum heatshield. You can buy Kydex T from Amazon and bend it to your heart's content with a heat gun.

For the intake itself, I still utilized the AEM Dryflow filter with Cobb's MAF housing and bracket but ditched Cobb's silicone hose for a 2.75" ID aluminum pipe and a couple adapter hoses.

Enjoy this little showcase of my progress. NO, I cannot make it for anyone. And YES, intakes require tunes. Speaking of tune, I will be jumping on the dyno next weekend for my ELH, EBCS, pump, and other mods. You can see my progress of my car @joe_awsiet, or search #octurbojoe on IG. You can also find more info behind my progress from my other thread: http://www.iwsti.com/forums/2015-sti...heat-soak.html

Material and parts list:

- 2 12"24"1/4" Kydex T sheets
http://www.amazon.com/Kydex-Velour-Texture-Calcutta-Specifications/dp/B00EZBW7G0
- 10 feet (or however many you wish to buy) of bulbed rubber edging
McMaster-Carr

- X amount of 1/2" long rivets from Home Depot.

- 1 can of VHT Wrinkle Black from any local auto parts store.


First, I had to redesign the intake hose and filter routing with my own piping and Cobb's modified bracket. No more insulated snorkus. It's also spoken for already.


I had a vision with a tiny post-it and a little photoshopping on my phone.


The infamous USPS Priority Large Flat Rate box returns. No CAD, straight up eyeball. (These aren't the actual measurements of the finished product, btw)


Measuring, cutting, bending, and riveting done in 8 hours.


4 coats of VHT wrinkle black surrounds it.


Here it is sealed up and ready to install. I was told it loosely resembled Grimmspeed's new 08-14 CAI...hmmm, not really.


The filter/MAF housing is fully sealed, separated from the aluminum piping via silicone hose, and isolated from the radiant heat.
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Old 07-29-2015, 03:26 AM   #36
joejoe69
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Multi-angles of this homemade porn.





Thanks for viewing. Now go get some Kydex T and start bending...
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Old 08-30-2016, 01:02 PM   #37
thejoninator
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Default Stage 1+?

Are you still running stage 1+sf with that metal pipe? I'm assuming since the sensor is before the pipe that the readings are the same?
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Old 08-31-2016, 11:03 AM   #38
Titter
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im trying to make one for my bugeye and i was struggling with what materials to make it out of...

i WAS struggling...

thanks to this thread there is no more struggle.

thankyou for this thread.
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Old 08-31-2016, 02:38 PM   #39
Alex05sti
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how about a long term write up, what have you seen over time?
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Old 09-06-2016, 05:27 PM   #40
Wyatt97
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Subscribed. This thing looks amazing. I have an old air box laying around that i want to cut up and see if I can get it to house my sf intake. Ill definitely try to make a kydex one if that doesn't work. Good work sir!
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Old 12-26-2018, 08:10 PM   #41
What could go wrong
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sorry to dig up a thread from 2 years ago, but I am curious as to how these are holding up? I was a knife maker for a good amount of time, so I can work kydex pretty well, but I would be concerned that the underhood temps of a wrx in the summer would soften the kydex to a concerning level... anyone have any warping/melting issues? thanks in advance!
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Old 12-27-2018, 12:46 AM   #42
joejoe69
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Still kickin. Search for Kydex 2.0 on here, been running it since 2015. Also follow my IG @octurbojoe. Left the forums long ago. Thanks for asking how it's holding up.
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