And installing an air intake on the hood is one of the elements of car modification. Such tuning will not only give the car more sporty features, but will also provide good cooling of the engine and turbine on hot summer days.
In order to make an air intake with your own hands you need following materials:
Thick film;
A container of polyurethane foam;
Fiberglass;
Mastic with fiberglass;
Putty;
Sandpaper;
Sharp knife.
Air intake manufacturing process.
1. Spread the film on the place where you plan to install the air intake (the film should cover most of the surface so as not to stain the paintwork with foam). Then apply the foam in an even layer on the film (try to make the shape of the workpiece you need) and let it dry.
2. After the foam has completely dried, we reveal the talent of a sculptor and give the workpiece the necessary shapes and outlines using a knife and sandpaper, until you get the part that you want to install on your car.
3. After the part is ready, it needs to be covered with fiberglass; if your product has a complex shape and sharp edges, then the thickness of the material should be 1-2 mm. In order to replicate the shape of the product as much as possible, and to ensure that the material fits as tightly as possible to the base, the fiberglass often needs to be cut. Depending on the type of fabric it is determined required amount gluing layers, the total thickness of the glued material must be at least 4 mm. Also, instead of fiberglass, it is allowed to use a bandage with epoxy glue, the end result is almost identical.
4. After pasting, the product must be allowed to dry thoroughly; depending on the temperature, this may take from one to three days. When the part is completely dry, you can continue working. First you need to remove the foam from the inside of the product with a knife, making a hole for air flow, and then you should sand it sandpaper the most noticeable irregularities.
5. Next you need to saturate the part with mastic and putty. The process is quite labor-intensive and the final result depends on it. For impregnation, it is better to use mastic with fiberglass; you need to apply it in a large layer; this will help hide the errors that were made when gluing with fabric. During impregnation, the part must be periodically applied to the place where it will be installed in order to immediately identify and eliminate irregularities (there should be no gaps between the part and the hood). Then we begin to fill small pores with putty, try to make the first layer as thick as possible in order to immediately fill all the pores and make the part stronger because it will experience strong loads at high speeds, and level the surface with the second and third layers. After drying, the putty should be cleaned with fine-grained sandpaper; if necessary, uneven areas should be puttyed so that the surface is perfectly smooth.
6. Next, the part needs to be degreased, primed, painted and varnished.
It is better to use rivets to install the air intake on the hood.
Air intakes on sports car models serve to provide additional cooling of the engine, components and mechanisms that become very hot under high loads. Often drivers of simple cars want to change things a little appearance, install a pair of spoilers, or an air intake.
First, you should know that these elements come in two types, differing in functional application:
an air intake that works to capture air flow; this option is installed if the intercooler located under the hood is in a horizontal position. In this case, a powerful air flow will effectively cool it; 
the second option works in the opposite direction, it pulls hot air from under the hood. This method is good when the radiator grille allows sufficient air flow to completely cool the engine. In this case, hot air will flow through the upper air intake. 
Before you start making an air intake with your own hands, you need to decide on its design that will suit your car.
The whole process will take place in several steps:
foundation education;
giving the desired shape;
fiberglass wrapping;
removing the base;
impregnation of the air intake shape;
applying varnish and paint;
installation of a cleaning mesh;
air intake installation.
Next we will talk about each manufacturing process separately and in detail.
Making the base.
To make the base you will need a can of polyurethane foam, a sharp knife and thick plastic film. After you decide exactly where on the hood the air intake will be installed, put a piece of film there, it will have to be larger than required, but you will not stain the hood. The film must be secured with tape, and polyurethane foam should be applied on top of it, then give it time to completely harden and harden. 
Creating a form.
Now this frozen foam needs to be cut and given the maximum shape of your future air intake. And don’t be afraid, you only need to give general outlines; minor defects will be covered later. You need to trim off the excess sharp knife. You should start from the bottom, firstly, this is the most difficult part of the work, and secondly, in case of failure, you can fill it again, and you will not regret the time spent. Don't forget to leave a reserve, because... Then you will shape it using coarse sandpaper.
Application of fiberglass.
Once you have the shape, you can move on to creating the part itself by gluing the workpiece with fiberglass. It is important to choose the right fabric thickness, taking into account the shape of your workpiece. If the shape is complex or angular, then it is recommended to use thinner fiberglass, approximately 1-2mm thick, this will allow you to more accurately replicate all the edges.
Accordingly, when using thin fabric, you will have to make several layers, and the total thickness of the layers should be at least 4mm.
Removing the base.
After you have completely covered the part with fiberglass, you need to let it dry thoroughly, usually for at least a day. Then you can continue working. Now you need to remove all the mounting foam from the inside, after which the inner surface needs to be well treated with sandpaper.
Impregnation and putty.
Typically, impregnation is carried out with mastic mixed with fiberglass powder, but you can get by simply mixing it with mastic for body work, proportion 3:2, three parts mastic, two parts body. During the impregnation process, the air intake must be placed at the place where it is installed, so it will be clear where to add a layer and where to sand it.
When the part is thoroughly saturated, you can proceed to puttying it. After the first layer, sand and lay the second, then the third, and so on until the right size. The first layer will be almost completely absorbed, because fiberglass absorbs putty very well, even after impregnation with mastic. It is necessary to fill all the pores of the fiber. The number of layers will give the part strength, which will be needed when exposed to a powerful air flow.
Coating with paint and varnish.
Before painting, you need to degrease and coat the part with primer.
The paint is also applied in several layers; it takes 15-20 minutes for the layer to dry. Finishing work, this is a varnish coating that is applied in the same way as paint, in several layers.
Installation of a protective grid.
An insect screen must be installed on the air intake. What section to choose the mesh and with what pattern is up to you. It is advisable to make a place for inserting the mesh into the part in advance, during the manufacturing process, but it can be cut at the final moment. We cut the mesh according to the shape of the entrance with a margin of 1 cm for fastening. The mesh is attached with silicone sealant or any moisture-resistant adhesive. Don't forget to paint the mesh in the desired color, usually black.
Air intake installation.
The product can be secured in two ways: through holes in the hood, followed by putty and painting. Either place it on sealant or double-sided tape.
A custom air intake on the hood can not only be a spectacular tuning of the exterior, but also have functional purpose. Let's look at how to make an air intake with your own hands and how to install the accessory so as not to cause harm paint coating car.
Make or buy
As practice shows, most often the air intake on the hood is just an addition to pre-installed body kits, arch extensions, etc. Therefore, choose an accessory to suit your taste among ready-made options difficult, and the cost of a finished hood in a non-standard design cannot be called humane.
Previously, we looked at the process, where the matrix method of manufacturing fiberglass parts was mentioned. The same method is suitable for creating reusable matrices of air intakes on the hood of a car. Below we will consider a simpler manufacturing method, which is better suited for working at home.
Materials
To make it you will need:
Question DIY painting In this case, we will not consider an air intake in the color of the hood, since this has already been said enough in the section.
DIY making
The air intake is made separately from the hood, since otherwise you simply will not have the opportunity to properly process the internal cavity or install a mesh. How to make an air intake on the hood: 
- you will need a stand on which layers of polyurethane foam will be applied;
- after drying, cut the foam with a stationery knife to the shape that will be the lower cavity of the air intake;
- wrap the mold with film;
- Apply sheets of fiberglass evenly with an overlap of 1.5-2 cm, soaking generously polyester resin each layer. Drying between layers is required. To make the surface more even in the future, after the resin has dried, it is better to sand off the humps and overlapping sheets a little. Try to place fiberglass overlaps in different places;
- after the last layer of fiberglass has dried, you can begin rough sanding;
- before puttying, the form can be corrected with technical plasticine;
- You should not expect that you will be able to putty and put the part under the ground the first or even the second time;
- for priming and is necessary special tool and understanding of the process, so it is better to entrust priming and painting to professionals. But if there are no special requirements for the quality of the coating, then the air intake can be coated with acrylic primer from a spray can and then painted with aerosol paint.
Even at the stage of manufacturing the mold, provide a cavity into which you can screw a self-tapping screw to attach the mesh. But you can do it much simpler - glue the mesh with epoxy glue.
What is the best way to attach it to the hood?
Many people consider installing an air intake by screwing it to the hood as vandalism. The bitterness is that sooner or later, pockets of corrosion will appear at the drilling site. It would be a good idea to glue the air intake to the hood, for example, with the same epoxy resin. But for this glossy surface The hood will have to be at least matted with sandpaper to ensure adhesion. If the accessory is installed on an unpainted hood, then this is not a problem at all.
It is best to use body sealant for fastening. It will hold the air intake quite firmly and prevent it from damaging the car’s paintwork. As a temporary solution, you can use 3M double-sided tape; to improve adhesion, we recommend a primer used when wrapping cars with vinyl film. But you should be prepared for the fact that the strength of the connection will weaken over time.
It is important to know
The biggest problem with most custom air intakes is the accumulation of dirt and leaves in the internal cavity. Also, do not forget about the aggressive road reagents with which roads are so generously treated in winter time. If in your case the air intake serves its intended purpose - it cools the intercooler, as is implemented in the Subaru Impreza WRX STI, or improves air flow to the air filter, and you had to cut a hole in the hood, wash the cavity with a car wash more often high pressure. Also take anti-corrosion measures at the cutting site and fastenings. When trying on the location of the cutout in the hood, be sure to focus on the internal stiffeners.
The first method of installing a real intake can have two scenarios. The first involves capturing air from environment, when the hood is located horizontally and the oncoming air flow cools it well. The second scenario is to install the air intake so that it draws the hot air left by the engine and carries it out through the "nostril" in the hood. At the same time, cool air passes through the radiator grille, cooling the engine.
Making an air intake is not difficult. You can, having thought through the design of the product in advance, easily make it. All work will be divided into several stages.
- The base of the intake is created.
- This very base is given shape.
- Fiberglass fabric is placed on top of the mold and covered.
- The internal blank is removed.
- The product is impregnated.
- Then it is covered with paint and varnish.
- The mesh is installed.
- A ready-made part is mounted on the hood.
The first stage is creating a base, which will require a thick film and polyurethane foam. But first you need to determine the place where you plan to install the new part. The film should be spread very carefully on the hood. This is done for the car. The film is attached using masking tape (after the foam dries, it will increase the strength of fixation of the air intake to the hood). The top is filled with foam. Then you should wait until everything cools down.
You can make the air intake separately, and only then install it on the hood of the car. Here it’s more convenient for anyone. If you are not confident in your abilities and are afraid of staining the surface of the car, it is better to do it separately, and at the end attach the air intake in the same way as described above.
Now the next stage is giving shape. After the block of foam hardens, you need to use all your imagination and cut off everything unnecessary from the form. It's clean creative work, very interesting and exciting. Experts advise starting to shape from the bottom part, which is adjacent to the hood, since it is more complex and in case of an error, you can start all over again. Shaping is carried out in several stages, and the very first involves grunt work. Then be sure to go over the surface of the form with fine-grained sandpaper, and then carve again. Everything is done until you achieve the desired result. It is recommended that you often check the photograph of the finished air intake that you are going to make.
Next, we give the product strength by covering it with fiberglass cloth. We take this fabric and paste over the workpiece. We remember what more complex form product and the sharper its corners, the thinner the fabric should be. You can even glue it with 1-2 mm thick material. During the gluing process, the fiberglass fabric is cut for a tighter fit to achieve clearer contours. Depending on the thickness of the material, we apply fiberglass fabric in several layers so that the product is eventually covered by 4 mm.
Fiberglass is not the only material that can be used to cover a semi-finished air intake. Epoxy resin and an ordinary medical bandage can also be replaced required material. The workpiece just needs to be greased with glue and a bandage placed on top. During the process, be sure to ensure that the bandage is completely saturated with epoxy glue. Then we apply a layer of glue again and another bandage on top. We do this several layers and leave to dry.
Once the glue has dried, we begin the sanding process. The entire surface of the product is sanded with coarse sandpaper. Where necessary, place a layer of putty and cover it. It is advisable to use car putties made with synthetics - they dry faster and provide a hard coating. In addition, such putty, when it dries, is easier to sand.
Again, the putty should be applied in two or even three layers. After applying the initial layer of putty and it, smaller flaws are discovered, to which putty is applied again. Finally it turns out high quality surface air intake.
Remove the inside of the product. We cut off all the excess and make a hole. It is not necessary to sand the internal space and, if desired, you can even simply go through the sandpaper to those places that are more convenient to reach.
The next stage of work is impregnation. It is believed that this is the most difficult part of the process, because in this case you will need to stock up on great patience. The final result will depend on high-quality impregnation. It is advisable to use mastic with fiberglass as an impregnating material. It is sold ready-made, but it is recommended to add some more regular mastic. For 3 parts of mastic, take 2 parts of body mastic and mix everything. We impregnate the product in several layers with this mixture, which will give the future air intake strength. Thanks to this, the product will withstand heavy loads exerted on it at high wind speeds.
Before applying paint and varnish to the product, you need to cover the previously degreased surface with a layer of primer. in several layers, taking a break of 15 minutes between them. It is recommended to paint the inside of the air intake first, preferably black, which will give the desired depth. We cover it with the same paint outside. After the paint has dried, varnish it, again in several layers and at similar time intervals. Let it dry thoroughly.
The installation of the mesh is carried out mainly to ensure that unnecessary objects do not fall into the air intake. You need to remember about it even at the stage of manufacturing the air intake, providing a protrusion for the mesh. When measuring and cutting out the mesh, you need to take into account a small margin of 1 cm, which will be needed for fixation. The mesh is attached using silicone, but you can use other compounds. The mesh can also be painted black beforehand so that it matches the air intake and gives a more attractive appearance.
At the end you need ready product secure well. To do this, you need to fix the air intake with bolts, and then putty the joints.
Installing the air intake in the second way
You can make the air intake differently. To do this, you will need to cut a hole in the hood, as when cutting out a hatch. It is advisable to make this very hole between the stiffening ribs using a grinder or jigsaw. The edges must be secured with a self-made or purchased air intake. Be sure to tighten with bolts. Such an installation will allow not only the entry of cold air, but also the exit of hot air.
As you can see, nothing complicated. The air intake is ready, and its manufacture does not take much time and effort. It's simple. Although this does not exclude the fact that you need to stock up on considerable patience, because not everything will always go the way you want. If defects are discovered during the work, they can be easily corrected with mastic, which will perfectly disguise everything. Knowing how to make an air intake on the hood, you can achieve an incomparable look.
First, do not forget to apply a layer of primer to the finished part and degrease the surface. Then we apply several layers of paint, maintaining intervals of about 15 minutes. Then we cover it with several layers of varnish at similar time intervals. Let it dry thoroughly.
Mesh installation
You need to attach a mesh to the air intake so that it does not serve as a trap for flies. You should think about its presence in advance, and do not forget to provide a protrusion for it on the part. When cutting the mesh, you should leave a small margin of about 1 cm; it will be needed when attaching the element. We secure it with silicone sealant, although if you wish you can use special compounds for these purposes. Before installation, the mesh can be painted black to give it a more attractive look.
Installation of the finished part
There are two ways to attach a finished air intake:
- Cut a hole on the surface of the body, secure the part with bolts, level and putty the joints.
- Secure the part with silicone sealant. For reliability, you can also use automotive double-sided tape, gluing it around the perimeter bottom part intake
It’s up to you to decide which of these fastening methods you choose, but it’s better to stick with the second option, because... Extra holes in the body can lead to unnecessary problems.
Now you know that manufacturing and installing an air intake, although labor-intensive, is doable. Be patient and don't panic if things don't work out as expected. After all, all imperfections can be corrected; mastic will perfectly disguise them.
Air intake for Subaru Impreza WRX
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