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This is a good DIY project if you have some basic tools and want to give it a go. I did this several years ago after reading a similar how-to that Dan Pilo wrote.
I started by mocking up the heatshield using thin cardboard. I used modeling clay to determine the height that the heatshield needed to be.
I made a second cardboard mockup to check the fit of the final design. Once I was happy with the fit, I made a master template to make it easier to transfer the outline.
I used a jigsaw with a metal cutting blade to cut the basic shape. I then drilled the mounting holes and the hole for the intake tube as it's a lot easier to do this on flat material.
The next step is to bend the flat sheet to it's final shape. I used 2 pieces of angle iron and a shop vise to make the bends.
This shows the final shape.
Here's a group photo.
The hole for the intake tube will vary depending on the size tube and filter you use. The stock rubber tube will accept a 2 5/8" OD tube. If you are using a Alta silicone tube you can use a 2 3/4" OD tube. I used a 2 3/4" OD by 2 1/2" ID aluminum tube with one end machined down to 2 5/8" to maximize airflow.
Here is a drawing of the flat pattern for the heatshield.
This was a fun project to do. My costs were as follows.
Aluminum sheetmetal $0
Aluminum tubing (2') $40
Rubber seal (20') $20
K&N filter $60
Total cost $120
Saved $80 over typical intake. I sold several heatshields to cover the material costs so it really only cost me some of my time.
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