Hi all,

Wasn't sure where to put this thread so if it gets moved, can someone let me know. thanks.

Recently I have bought an aftermarket Intercooler for my Bug.

The thing was though I had a standard WRX undertray and the STi one is the complete wrong shape.

The problem with buying an aftermarket I/C, the undertrays are sometime not supplied.

If you can find one suitable for your new I/C, they still turn out to be very expensive.

Alot of people hack away at their standard undertrays and sometimes it may look a bit of a bodge job, or there is not a good enough seal, as well as being time consuming.

Im in the design business and have designed my own undertray with correct measurement for my car's bonnet and my intercooler.

I have a chap who will be manufacturing it for me in the next week at a reasonable cost I think.

If I can come up with a standard form / detail which people could put their measurements on and post back to me, would anyone like to try this out?

Cheers,

Ben

 

I guess you'd need to define "reasonable cost" mate

 

oooops, forgot that part lol.

Well the one i have designed for a massive Hyperflow copy I/C the bloke can make 1No @ £75 delivered.

But could maybe get it at a better rate if I could make 10 or more at once i.e group buy...??

What do you think? I would appreciate comments.

I will also email people with a PDF of what the pieces will look like if needed.
PM me or add ur email on this thread and i will send out the designs. The design / drawing is copyrited.

Ben

 

Just to add, the material will be 1.2mm thk Aluminium - Mill finish.

 

You may wish to consider using a material more robust than 1.2mm sheet aluminium.

 

Why's that mate?
With putting bends in the metal strengthens it. The original undertrays aren't much thicker are they? Plus looking to keep cost and weight down.

And its not they will be under a load of pressure or strain....??

These will also some with expanding foam tape to give a secure seal.

 

I made mine from 1.2mm stainless but mainly because there is a splitter section in the centre which bears some of the force from the air ducted by the scoop. If you're not intending on installing a splitter then you may be ok with ally.

Standard ones aren't much thicker but are mild steel IIRC.

 

I asked about S/S and he wasn't overly keen on it, I didnt ask why.

Where do you mean about the splitter matey? have any pics?


My bad about the original ones, thought mine was ally.

if u PM me ur email addy i'll show u what my design is like..
Ben

 

Splitters make the duct / intercooler more efficienct. Try a magnet to the OEM duct, if it sticks it's steel. My duct and email etc is on my website.