Sorry...more pictures now...

 

Yeah, it take me a while to get the pictures uploaded. If anyone wants higher resolution pics send me a pm with your email address and what pics you want and I'll send them to you.

 

Looks good! I wish I had the tools and time to tinker with something similar for my truck.

 

It's not that bad. It might look a little rough around the edges, buy you could do this with a pair of tin snips, pop rivet gun and a pair of pliers. I'll assume you already have a pair of pliers so maybe another $20 in tools and you're set.

 

I have all the tools you mentioned- now for the time...

 

Then it's just a simple matter of cutting the pattern and making a 1" 90 deg. bend where one piece joins the next. If you use pliers to make a 90 deg bend you need to work your way down the length putting a slight bend, about 5 deg. with each pass until you have the 90 deg bend. Once you get the 3 sides made you can pop rivet them together. I've got some fancier equipment but made it out of 3 pieces for anyone who wanted to duplicate the process. Here's a shot of the side piece. I've got a few more pictures I'll upload to the gallery from the original cuts. Some of those dimensions may require additional trimming.

 

I'll basically have to start from ground zero because I'm trying to retain the stock battery tray- it might be easier to pitch it though.

 

Look at the pics in my gallery. See where the bottom of the box rests on the fender under the filter? Lay something horizontally across the rails that come off the battery box and figure out how high off the fender you are from the bottom of where my box would sit. Then just subtract that distance from my measurements. The bottom of your tray would probably need to stop at the inner (motor side) rail from the battery box (if I remember the set up correctly) so the filter can still rest on the fender. I did leave 1" clearance from the top of my box to the hood so I could add some rubber weatherstripping later. Also as mentioned earlier, make something out of cardboard first to see if it fits.

 

You have to go back to my "minimal radial clearence" comment. You want as much space around the filter as possible therfore; you SHOULD move the battery tray.

Did you see that! I used a semicolon!!! (I will have to ask the English teacher wife of mine if I used it properly...)

 

nice!

 

To let everyone know Marc, (mudmaker) has done the first set of drawings for the template. He's got them broken down onto regular 8 1/2 x 11 paper that you can tape together for your template.

If the weather's not as bad as they're forecasting I'll print out his template tomorrow and see how it compares. As soon as we've got any revisions done one of us will post the templates here for anyone who wants to make one of their own.

Make sure you leave him some rep points for the work he's doing on this.

 

We have a template of Chris' prototype airbox complete. Just print out each page on 8.5 by 11 paper without using any print scaling. There are 9 pages for the side and bottome and 6 for the back. Once printed you will see where you can cut on the light grey line so the sheets can be taped together.

Here are some of Chris' pics of the templates taped together.

 

Make sure you give the rep points to Marc on this one. He spent some time on it. I actually think I spent more time cutting and taping these things together than I did building the box.

Once you get everything cut and taped together you can lay it on top of your piece of metal and using a hammer and punch, tap all the corners and fold lines with the hammer. This will leave you with little indentions on your metal. Then take a marker and ruler and connect the dots.

You can buy some sheet metal bending tongs at home depot or use a set of pliers for your bends. The trick is to make small, 5 or 10 deg bends, up and down the line so you gradually bend the angle up to 90 degrees. Unless you find something that can clamp the full length of the bend, it will end up crooked. You'll also need a drill, drill bit, some pop rivets, and a pair of tin snips.

Since my truck doesn't have the factory air box, some of yours may fit different. The good thing is you can always trim it down if needed. If you buy galvanized sheet metal wipe it down with vinegar before you try and paint it. Galvanized metal comes with a light oil coating on it to prevent rusting during transit and storage. The vinegar will remove the oils.

If anyone has any questions let me know.

 

Nice work Mudmaker! What exactly is print scaling??? If I had to guess that means just open them and print

 

Just open and print