Reply With QuoteNext step was to try an introduce a little more under-bonnet airflow.
Even with Dynamat Extreme and Dynaliner in the footwells, the driver and passenger toes get a little toasty.
Once sucked by the thermo fan through the radiator and intercooler, the now hot air needs to go somewhere. Most of it logically flows between the RHS guard and RHS floor. Hence the driver gets hot feet.
It's not much better for the passenger, with some of that air wrapping behind the engine block and being added to by the heat coming off the turbo and exhaust manifold, before taking a similar exit.
To try and improve the airflow by introducing a low pressure zone, I decided to add a vent to the LHS Guard.
First up I secured a 200tdi Defender Air Intake Cover. If I was a perfectionist (or I had the cash) swapping out the LHS guard for a 200tdi guard would have been perfect.
Rather my second step was to check out a few pictures online to make sure I was lining up my cuts with where the air intake would be. Drawing the lines made it all feel very real.
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The point of no return! The third step was to get the drill out and establish a pilot hole
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Then crack out my new sheet metal nibbler cutter. These are most commonly used by roofers and fencers to trim Colourbond sheets and panels. These simply attach to your drill (just like a drill bit), you stick it in the pilot hole and pull the trigger. You steer with the handle.
A small start ...
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And the final 'hole' post filing.
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Finally I didn't think that the factory part had enough strength for pop rivets, so I liberally applied black silicon to 'glue' it in place. It was held in place with tape overnight while the silicon set.
Not quite "Factory Fit" finish, but not too bad either.
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Total cost: Under $100 (if you have to buy everything including tools)
Time spent: Under an hour
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