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JDM Design

 

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Mazda3 RADIATOR SHROUD

SEDAN DESIGN

The following files are property of flex innovations and may only be used for personal use.

The following design is the BETA design version 1.0

It's actually the 3rd version, and although it fits ok, it's not MACHINE perfect...  yet.

  1. RADIATOR SHROUD PAGE 1
  2. RADIATOR SHROUD PAGE 2
  3. RADIATOR SHROUD PAGE 3

Here is print that breaks it up into 4 pages.  Somebody pointed out they couldn't get the above three images to fit on one sheet, so I made this one:

  1. RADIATOR SHROUD 1
  2. RADIATOR SHROUD 2
  3. RADIATOR SHROUD 3
  4. RADIATOR SHROUD 4

Quick and dirty walkthrough:

  1. Choose a material:  I chose a galvanized steel panel that felt like 20 gauge or thinner from my local home improvement store.  (Lowes or Home Depot)  I know it's not the best material, but I'm making a prototype after all and the real deal is going to be 0.05" aluminum.
  2. Print my handy template onto 3 sheets of 8.5x11 paper.  Tape them onto your steel panel, FRP, or fiberglass.  Make sure you check the bar scale I put on the first sheet that it matches a ruler.  This is a little handy trick of checking the correct scale of the plot.
  3. Drill the holes.  You actually don't have to cut a SQUARE, I just made a circle there and it fit fine.  I used a hole punch and die.  My set cost around $26 from Harbor Freight.  It's basically an industrial hole puncher that you use a hammer to punch a steel cylinder through a hole making a HOLE PUNCH in your sheet metal.  It's a little slow using it, but the holes are great quality and better than if I used a drill.  If you use a hand drill I recommend Milwaukee drill bits.
  4. Cut the pattern out.  If you're using a jigsaw/sabresaw, wear eye protection.  You can also use a nibbler, or if you've got a metal shop, then use a metal band saw.  If you're using tin snips (LIKE ME) then make sure you get a pair of GREEN and RED handle snips.  Tin snips make a decently clean cut very fast and it's the cheapest route to go with if you have no tools.
    bulletGreen snips cut clockwise. 
    bulletRed handle snips cut counter clockwise.
    bulletTIP: Wiss is a good brand and I've had a pair that's like 8 years old and still works great.  You can buy some cheap aviation tin snips for $8-10 if you go with chinese steel from Harbor Freight or an import brand like "workforce". I'm not sure if these will cut as well and last as long as "Wiss".
  5. Use a file to sand the sharp edges down.  You may also use a dremel if you have to grind down material to make the right radius's and curves.
  6. Use a metal primer and automotive paint.  If you want you can use engine paint that may be more durable in the long run.
  7. Installation.  TWO screws, just slide it in.  Optional:  Depending on the material you used, you might want to secure the front of the shroud to the grille with some double sided foam tape, or if you want to make your own method of fastening.

 

If you want to give back to the race for the cure for JDM mods, then here's the button for you: 

Chris

Flex Innovations

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Last modified: 03/24/10