After driving around for a few weeks in the summer heat, I've realized that the JWT Popcharger is in desperate need of a new heat shield.

So, what I am working on, is just that.

Keep in mind that this is only a prototype, and it's not very pretty. The final design will be made out of 5052 AL.


After installing the shield and driving around for a while, I could definitely feel an improvement. The "lag" that a heatsoaked air filter causes was greatly diminished.

I let it sit for about 10min, idling with the cooling fans on, then popped the hood. The heatshields were too hot to hold your hand on for any amount of time, but by reaching through in air duct, I could feel the air filter, and it was right around ambient temps.

I do plan to use a pyrometer on it, as well as an OBDII datalogger, to see what kind of reduction in temps this gives.

Just from what testing I've done so far, this seems like a big improvement.

I'll update this thread as testing progresses.

-Tim

 

Looks very promising. Are you thinking of going into production with these? Just think how many people have pop-charged Z's...Do it. I'll buy one.

 

It's a good possibility.

I'm an Engineer for a small/medium sized company, and most of the work we do, involves custom sheet metal parts. Though, we've never done anything for the automotive industry. We do have our own production facility, that is available to me after business hours. I could do a run of 100 or so every couple days if there was a demand for it.

I'm going to keep tweaking this proto for a few days, and build a CAD model that I can laser cut and bend. I'll post up some pics to see if anyone is interested in one. I'll also post up the data logs.

-Tim

 

Sounds good man! Keep me posted. I'd be happy to do a test fit of your pre-production model just to make sure it works and is user-friendly.

I assume you would make this out of sheet aluminum to keep weight and costs down?

 

I'm in too! Nice work Op.

 

I'd also be happy to test fit the prototype and review it.

 

I'll keep you in mind for that.

This would be made out of 5052 Aluminum Sheet. 3003 AL would be a little cheaper, but it doesn't have the corrosion/oil/gas resistance that 5052 does.

Installation should be a 5 min job. It will attach to the existing Popcharger Heat Shield in the same way that the Popcharger Shield attaches to the seam of the car body. A simple clamp. That will eliminate any drilling.

The other side will require loosening the 10mm bolt that holds the MAF bracket to the body, and slipping the heatshield in place. Then, just tighten the bolt.

I'll throw up some CAD drawings tomorrow evening to clarify what I am talking about.

-Tim

 

Interested in this.

 

Nice

 

Looks good. Would laterally ribbed aluminum be effective?


Since you seem to be into fabrication... Have you ever thought about fabricating an aluminum vent that goes from the center grill that leads incoming air up to the intake hole in the front radiator brace?

 

Looks really good.

 

not to bad for a prototype. keep up the good work

 

Looking good so far. CF would be even nicer since aluminum is such a great heat-sink transmitting engine bay heat to the inside of the air box.

Any pics of the back? I'd like to see how it's sealed against the base of the poop charger.

Thx.

 

Looks good so far. I'm def in if you decide to start producing them.

 

Yes but doubtful since he said he works for a company that produces custom sheet metal parts. You can always go the Mishimoto or Gruppe-M route.

As long as he doesn't make it look like a heatsink most of the radiant and convection heat should be blocked. Conduction is possible where it contacts the Popcharger, but that can be minimized with a rubber ring.

 

Just an update:

I had a chance to drive the car some more with the heatshield in place. In stop and go traffic, with the A/C on, it was obvious that there was a difference in the level of heatsoak that I usually see.

Once I got to my destination, I popped the hood, and the shields were so hot, that they would actually burn you if you were to hold a finger to them.

The air filter was a little warmer than ambient, but it was drastically cooler than the shields.

I know, I know, that doesn't mean anything until I can get a pyrometer on there for some real world numbers... Which I plan on doing within the next couple of days.

So far, I've not had much time to work on this due to a very heavy workload, but I should have some time later this week.

Here are a couple of renderings of the progress I've made so far. Hopefully this will clarify how it will attach to the existing shield, and the OEM airbox tab.

I've still got to make another proto to test with, because there is one more bend needed, to make the front of the shield meet up with the core support. Once that is in place, I will be able to make the cutout for the MAF sensor.

I'll keep you updated as I progress.

-Tim

 

Looks very promising, will the final piece be made of plastic?

If not will there be a coating on the metal to prevent it from absorbing all that heat?

 

Tim, do you remmeber what was the temp outside? and how long did u drive?

Keep update for us.


-JLee

 

So instead of the hood , your going to make a different top for the normal heat shield.

 

in development for the HR motor?