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DIY: Do It Yourself
Post here to share or improve your wrench turning skills! All BMW E46 DIY tips, tales, and projects discussed inside. Learn to work on your car and know the right BMW parts you will need!

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Old 05-21-2006, 11:14 PM   #1
ajlman
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K&N Filter Heat-shield DIY+PICS+Measurements

E46 custom fabricated heat-shield for K&N (or other) “velocity stack” filter

http://forum.e46fanatics.com/attachm...1&d=1148269914
IMG_0097.JPG

Parts used:
K&N filter PN# RX-4990 $74.99
(I selected this one because of the extra filter element in the front most 3” filters will work)
Spetcure ind. Chrome intake hose (from Pep Boys Auto) $4.99
‘2x’3 piece of sheet metal: $11.99
Tube of 3M seam sealer: $3.99
“Door edge guard” two pacs: 1.99 each
Automotive primer and paint: $6.99
1/8” POP rivets

Essential Tools:
A sheet metal “body hammer”
Pneumatic sheet metal shears, nibbler, or cutter
(If you don’t have air tools a manual shears will get you buy)
Metal shears
POP rivet gun
Pneumatic or electric grinder
Workbench, vice or block of wood to bend metal
Large channel lock pliers
Work gloves
Patience and determination
A case of beer


1. Remove stock BMW air box and inlet hose, do not remove MAF sensor it’s positioning in relation to the shield is critical as it also serves as a mounting point.

2. Cut (2) 15x15 pieces of cardboard. There are two main parts to the shield that will eventually need to be wielded or riveted together. First, you’ll need to fabricate both out of cardboard and trace the patterns to sheet metal. I’ve provided hi-res pics with horizontal and vertical measurements that reflect the fine-tuning and adjustments I made while fabricating the sheet metal.


jpg.gif IMG_0104.JPG
*For future reference the MAF side will be piece ‘A’ and the alternator and radiator side piece ‘B’*

3. The “solid” lines are vertical measurements and “broken” are vertical
This should get you close. You’ll need to test-fit and make necessary adjustments. Make notations with a sharpie, e.g. the high and low spots on the radius of your shock tower apron. Get it as close as possible while in easy-to-cut cardboard form.


http://forum.e46fanatics.com/attachm...1&d=1148271121
IMG_0116l.jpg
4.Same with piece #2 and double-check your clearances etc.

http://forum.e46fanatics.com/attachm...1&d=1148271121
IMG_0117l.jpg
4. Now the easy part is over! It’s time to trace your renderings to sheet metal. Make your rough cuts, hopefully with power or pneumatic tools! Remember, Measure twice cut once!
http://forum.e46fanatics.com/attachm...1&d=1148271121
IMG_0118l.jpg
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Old 05-21-2006, 11:25 PM   #2
ajlman
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5. Make a 90 deg. 1” bend near MAF in piece “A” (apron piece) where piece A and B will attach.


http://forum.e46fanatics.com/attachm...1&d=1148271360
IMG_0098.JPG

6. Make a 90 deg. bend at the bottom of piece “B” where it will sit on the rubber grommet that the stock air box used to sit.

http://forum.e46fanatics.com/attachm...1&d=1148271811
IMG_0121.JPG

7. Make another 90 deg bend and a 60 deg. bend for radiator tank clearances. I split this and bent the edge for filter clearances also.


http://forum.e46fanatics.com/attachm...1&d=1148271419
IMG_0102.JPG


8. Once both pieces ‘A’ and ‘B’ are fabricated test fit again checking clearances for wiring, hoses, etc. And trace you MAF and Intake hose with a sharpie.

9. Cut the intake and MAF holes by clamping in a vice and drilling a ½ (or larger hole and cutting with hand shears.

10. Clean up all sharp edges with a grinder.


11. Clamp ‘A’ and ‘B’ together with a vise grip

12. Test fit again and verify fitment (with the vise grip are facing up and inside)

13. Spot Wield or Drill 1/8 holes and POP rivet.

14. Once wielded or riveted make final adjustments such as the slight bend I made to piece ‘A’ where the K&N sticker is.

15. With the box in place verify a critical clearance point with a power steering hose (in front of the radiator tank) is not touching. With your finger locate the mounting hole in the rectangle rubber grommet where your stock air box mounted. With the shield pushed far enough forward (not touching the P.S hose hold your finger in place on the shield removing it. That’s where your bottom-mounting bolt will be located.

http://forum.e46fanatics.com/attachm...1&d=1148271693
IMG_0101.JPGhttp://forum.e46fanatics.com/attachment.php?attachmentid=180909&stc=1&d=1148271529
IMG_0108.JPG

16. Draw an X with a sharpie drill a 3/8 hole and slot front two back with a die grinder so you can adjust it once the bolt is seated in the grommet. (I did not provide measurements for this since your grommet may have aged differently over time.
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Old 05-21-2006, 11:32 PM   #3
ajlman
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16. Draw an X with a sharpie drill a 3/8 hole and slot front two back with a die grinder so you can adjust it once the bolt is seated in the grommet. (I did not provide measurements for this since your grommet may have aged differently over time.[/QUOTE]
http://forum.e46fanatics.com/attachm...1&d=1148272008
IMG_0103.JPG

*As far as the fabricated metal tube at the mating point with the intake hose I left out of this DIY due to the change in 2001. The one I made was basically a rectangle piece of sheet metal bent on 4 sides and attached with tabs.

http://forum.e46fanatics.com/attachm...1&d=1148272219
IMG_0101.JPG

17. Fabricate a 1” x 3” strap for the “topside” mounting, clamp in place drill and fasten with rivets.

18. Once all you mounting hardware is complete test fit one last time clamping the filter and make sure your shield has no sharp edges that will cut into hoses or wires etc.



19. Remove from car and scuff metal with a scotchbrite (not steal wool) pad, this will provide better adhesion for the primer and remove oils.

20. Spray 3-6 coats of automotive or professional grade primer, 10 min between coats. Allow a few hours dry time apply Automotive Seam sealer to seal all seams. Allow seam sealer to dry overnight.

21. Scuff primer with a scotchbrite pad and paint!

22. I used door edge guard around the edged of the box when finished.



I hope I covered enough, feel free to PM me with any questions!

-Aaron
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Old 05-22-2006, 02:31 AM   #4
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nice
great writeup
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Old 05-22-2006, 09:18 AM   #5
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Awesome bro
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Old 05-22-2006, 06:32 PM   #6
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thanks bro, ill be doin this mod this weekend.
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Old 05-23-2006, 07:22 PM   #7
ajlman
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Quote:
Originally Posted by jeremysmith1967
thanks bro, ill be doin this mod this weekend.
Hope it helps...It looks more difficult than it is. I had two evenings or approx. 8 hours into this not including primer or paint. Post some pics when your done.

-Aaron
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Old 05-23-2006, 08:02 PM   #8
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i will
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Old 05-23-2006, 11:11 PM   #9
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This gotta be one of the best DIY's!!! Looks OEM.
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Old 05-23-2006, 11:31 PM   #10
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everything installed pix?
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Old 05-24-2006, 02:29 PM   #11
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Quote:
Originally Posted by BMWintoxication
everything installed pix?
Thanks for the kind words everyone.
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Old 05-24-2006, 02:32 PM   #12
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That looks surprisinly good! Thanks for the writeup!
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Old 05-24-2006, 02:46 PM   #13
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looking good, hows the temp with that heat shield on now?
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Old 05-24-2006, 03:40 PM   #14
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looks great! thanks for the excellent writeup. will have to do this soon!
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Old 05-24-2006, 06:49 PM   #15
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Nice DIY!
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Old 05-24-2006, 10:58 PM   #16
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I have had a K&N intake for my 04 330i and it came with a heat shield and a lot bigger filter element then that http://www.knfilters.com/search/prod...x?Prod=63-1112
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Old 05-24-2006, 11:00 PM   #17
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very nice
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Old 05-25-2006, 10:51 AM   #18
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i was thinking of doing this and putting heat reflective covering on the outside of the heat shield
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Old 05-25-2006, 12:12 PM   #19
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Quote:
Originally Posted by Timbo126
I have had a K&N intake for my 04 330i and it came with a heat shield and a lot bigger filter element then that http://www.knfilters.com/search/prod...x?Prod=63-1112
The "K&N Kit" filter is slightly longer but the one i used has an extra filter element in the front. If anyone is thinking of fabricating this with the filter PN# that comes w/ that kit you'll need a 60 deg. bend in ith tube between the MAF and filter due to clearence issues w/ the headlight adjusters. Mine was 40 deg.
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Old 05-26-2006, 06:12 PM   #20
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Measurements?

Do you have the measurements for where I've indicated on the second piece?
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