Homeade intake plate: Lexan>aluminum

Old 06-21-2009, 10:44 AM
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Homeade intake plate: Lexan>aluminum

Here are some pictures of the lexan plate I made yesterday. Thought I would post some pictures. Its not finished as I need to re-bend one of the wings on the ride side for better alignment. I will be making a fiber glass "snorkel" to pass through the factory air guide and extend to the lower section of the bumper. This will be there to "feed" cooler air to the new plate. I was going to make a full snorkel similar to the spoon/muz, but after looking at the bottom of the hood(the angled cross section acts as the top of a snorkel) I decided that adding the snorkel would only restrict airflow as it passes over the radiator cradle....Hence the pinched area in almost all snorkels. I dont want to cut the hood for a larger snorkel, so I made this plate similar to the aluminum one that has been produced. However, being lexan it does not absorb as much heat as one made of metal. I left the plate clear for now, but I may paint it semi-gloss black to match the air box. I kind of like it clear too, it does not stand out so much. Sorry for such crappy/somewhat repetitive pictures. Wanted to show fitment.
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Old 06-21-2009, 12:41 PM
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Interesting. Nice job.
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Old 06-21-2009, 12:55 PM
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I like it. nice job!!! how did you cut the lexan? They always crack when I try to cut them. LOL
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Old 06-21-2009, 01:40 PM
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Thanks guys! Well I know that acrylic/plexiglass will crack/break/chip when trying to cut or be folded. Polycarbonate(lexan) will not.
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Old 06-21-2009, 07:02 PM
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plexi can be bent and cut without chipping.
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Old 06-21-2009, 08:41 PM
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Originally Posted by s2000isu View Post
plexi can be bent and cut without chipping.
sorry man, plexi/acrylic will break if bent. i deal with plastics at work everyday. poly/lexan will bend, especially when heated. i made my own cold air intake from home depot/ lowes 4" tube. it scoops air from grill, and hauls *** on highway. take-off from stop is a lil sluggish now though
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Old 06-21-2009, 08:44 PM
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Plexiglass has to be scored along a straight line and bent/snapped for a clean cut.
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Old 06-21-2009, 08:48 PM
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s2k1185, great job but let it go, the stock airbox is part of the governor, it restricts the airflow on purpose. take the top off and floor it on the highway, you'll see the high flow diff.
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Old 06-21-2009, 08:49 PM
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Originally Posted by TheCarGuy2021 View Post
Plexiglass has to be scored along a straight line and bent/snapped for a clean cut.
true. i operate a cnc router, i cut it with a special carbide bit
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Old 06-21-2009, 08:57 PM
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Originally Posted by PRB2000 View Post
sorry man, plexi/acrylic will break if bent. i deal with plastics at work everyday. poly/lexan will bend, especially when heated. i made my own cold air intake from home depot/ lowes 4" tube. it scoops air from grill, and hauls *** on highway. take-off from stop is a lil sluggish now though

take some pic i'd like to see it.
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Old 06-22-2009, 05:21 PM
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scroll right, engine is dirty...... i like to OFF-ROAD

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Last edited by PRB2000; 06-22-2009 at 05:27 PM.
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Old 06-23-2009, 12:09 AM
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The factory airbox is apparently good enough for Spoon Sports to use it on their endurance race cars. Along with a similar designed plate.

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Old 06-23-2009, 05:22 AM
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they only use their own parts, if they dont make an intake they leave it stock, plus those cars have regulations, there's only certain parts they can use to keep the race fair. notice there is no turbo, its like import nascar

Last edited by PRB2000; 06-23-2009 at 09:13 AM.
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Old 06-23-2009, 09:08 AM
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Check out puddydad's airbox all clear and lit, when the designer of the S2000 saw that he got a big smile and spent some time discussing it with puddy. They got some great pics together at the st pete gp.

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Old 06-23-2009, 09:55 AM
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Ok ill let the plexi guys at work know what they are doing is not possible thanks for the heads up.

Plexi can be bent. If it is heated correctly it will bend. Maybe not in an extremely sharp angle but it will bend. As thin as that material is I would imagine that you could get a nice radius if you heated and bent the plexi. Also at work we make clear boxes all the time with plexi that is cut on a table saw the edges need to be finished but they look crystal clear and have no chips when theyre done.

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Old 06-23-2009, 10:03 AM
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Originally Posted by PRB2000 View Post
they only use their own parts, if they dont make an intake they leave it stock, plus those cars have regulations, there's only certain parts they can use to keep the race fair. notice there is no turbo, its like import nascar
oh no you didnt

gonna **** off some folks mentioning NASCAR here!! hahaha
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Old 06-23-2009, 10:06 AM
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Everytime I've hadda bend plexi I've jus' used'a heat gun'n'z farr'z chippin' . . maybe if yer usin'a prunin'-saw'r'n axe.
Iff'yer doon'itt like yuh wanna have good resultz it'll work out fine.
'Lookz good 1185

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Old 06-23-2009, 10:10 AM
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we used cheap plastic in wood shop all the time to make things, however we had a line bender or strip heater

whatever i dont remember what it was called but it looked like this

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Old 06-23-2009, 01:19 PM
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Originally Posted by s2000isu View Post
Ok ill let the plexi guys at work know what they are doing is not possible thanks for the heads up.
maybe we aren't on the same page, i'm talking about acrylic. modified SG or not. they don't even attempt to bend it at my work. we use fairly thick material too. sorry....geeez

Last edited by PRB2000; 06-23-2009 at 01:26 PM.
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Old 06-23-2009, 02:55 PM
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Forgive the ignorance, but plexi'z plexi'n acrylic'z like Lexan, right?
'Never bent Lexan, but . . they've godd'a whole buncha thingz'n stuff made oud'uv'itt . . right?
Somebody'z bendin'itt.
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Old 06-23-2009, 07:02 PM
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oh just to throw my .02 in poly base FR resin bonds grat to plexi encase anyone wants to glass over it for tuffer part
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