Another fairly straight forward write up, but I figured at least one person may be interested in it (I was looking for one to no avail these past couple of months). This is a rear bumper exhaust heat shield install onto an aftermarket 240sx coupe rear bumper, but should be applicable to fastbacks, s14′s, oem/aftermarket, and other cars.
The motivation for creating this heat shield came from my exhaust warping the stock rear bumper – and melting/bubbling the paint on my aftermarket rear bumper. This was mostly due to the overly rich tune from the ecu install, but it was easier for me to temporarily install a heat shield, which may be useful later as well, than to tap the downpipe & tune everything now.
I bought a sheet of aluminum (.090″ x 12″ x 24″) for just under $20 delivered via eBay. I got this thickness because I read about how some were too thin – this may actually be a little too thick for some applications, but worked fine for me. I held it down via 5/32″ long aluminum rivets & 1/8″ medium & short aluminum rivets (you may also get away w/ medium, and possibly short, 5/32″ aluminum rivets).
Total Project Time:
This took me about 2 hours taking my sweet ass time with the hand / hack saw & 30 minutes of which was spent going to Home Depot to pick up rivets since I forgot where I put my other pack of rivets from way back when.
- Dremel, jigsaw, hack saw, or any other cutting tool you prefer
- Drill w/ 5/32″ & 1/8″ bits, or whatever size rivets you want to use
- Rivets & riveting tool
- Cardboard/paper for creating a template
- Aluminum sheet (again, mine was .090″ x 12″ x 24″)
- Dry erase marker or something to trace the template onto the aluminum
- Optional: I also used a section of aluminum heat shield barrier with adhesive (used for protecting areas in the engine bay from turbo installs)
I found it much easier to remove the rear bumper than to work with it on the car.
Failed attempt of using purely aluminum heat barrier with adhesive (ripped off @ Horse Thief Mile & took some paint with it).
Create a basic template of what you want your shield to look like with cardboard or paper.
Once you are satisfied with your mock up, trace the design onto the aluminum sheet.
Cut away! I first used a dremel with the jigsaw attachment, but I ended up using an old fashioned hack saw. After that, I smoothed the edges with the Dremel w/ sanding & deburring attachments.
Bend the aluminum sheet if necessary for your application. Then, test fit the sheet onto the bumper. At this point, you can drill pilot holes – drill onto the sheet first, then from there, drill through the bumper & place the rivets by hand to hold the position of the sheet.
Finish up by riveting. In my case, I added the optional heat barrier at the bottom of the bumper so that I didn’t have to bend the thick aluminum to cover that area.
Reinstall the bumper on the car. Take some pics and go “oooo, aaaaa”.
Don’t mind the crooked rear bumper – just look at the heat shield, haha.