You LT guys have it far too easy to get fresh air crammed into the stk air box or your aftermarket intake. I've been wanting to do something similar to my intake system for awhile, but doing it with a fog light was going to be a good bit of work. I decide to tackle this after work last night.
I made a pattern out of poster board, laid it over the area I intended to cut out, and used an air saw and cartridge roll to cut and smooth the area out.
After I got the hole how I wanted it, I used automotive door edge guard to outline the hole I'd made and give it give a clean look.
I then lined up the panel and outlined the hole I'd made on the underlying bumper and repeated the first process.
I took a 2.5" piece of aluminum and hammered out a very similar shape to my bumper hole and checked alignment. This is the beginning of the actual duct. I then put a silicone coupler at the end and clamped it down.
Once satisfied with that, I welded on a couple tabs for attachment and riveted the front part of the duct to the bumper.
I then cut a 45deg bend down to complete the duct. A 2.5" silicone coupler will slide into the factory duct once all the baffling is removed(MAJOR pita!), and the 45 slides into the silicone at the front half of the duct and at the air box duct.
I welded on a piece of 3/8" tubing to the 45 that inserts into a factory grommet to provide support.
I then cut out some mesh I had lying around, painted it black and riveted that to the bumper cover to keep it in place.
The last step was to re-install the fog light cover.
I made a pattern out of poster board, laid it over the area I intended to cut out, and used an air saw and cartridge roll to cut and smooth the area out.
After I got the hole how I wanted it, I used automotive door edge guard to outline the hole I'd made and give it give a clean look.
I then lined up the panel and outlined the hole I'd made on the underlying bumper and repeated the first process.
I took a 2.5" piece of aluminum and hammered out a very similar shape to my bumper hole and checked alignment. This is the beginning of the actual duct. I then put a silicone coupler at the end and clamped it down.
Once satisfied with that, I welded on a couple tabs for attachment and riveted the front part of the duct to the bumper.
I then cut a 45deg bend down to complete the duct. A 2.5" silicone coupler will slide into the factory duct once all the baffling is removed(MAJOR pita!), and the 45 slides into the silicone at the front half of the duct and at the air box duct.
I welded on a piece of 3/8" tubing to the 45 that inserts into a factory grommet to provide support.
I then cut out some mesh I had lying around, painted it black and riveted that to the bumper cover to keep it in place.
The last step was to re-install the fog light cover.
