DIY / How To: 240sx Rear Bumper Exhaust Heat Shield Install

[onosqv]

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.

Write up (links to larger pics) on my bloggy: 240sx rear bumper exhaust heat shield install

Total Project Time:This took me about 2 hours taking my sweet *** 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.

Tools:- Aluminum sheet (again, mine was .090" x 12" x 24")- Cardboard/paper for creating a template- 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- 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)



Step 1: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).

Step 2:Create a basic template of what you want your shield to look like with cardboard or paper.



Step 3:Once you are satisfied with your mock up, trace the design onto the aluminum sheet.



Step 4: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.



Step 5: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.









Step 6: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.



Step 7: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.

[kpariaug]

[kpariaug]

J/K J/Knice diy. good thing you did this now before it melts the bumper. too late for me, now i have to make one to cover up the melted spot.

personally i would rather have a rounded angle top with more rivets and the metal in flat black.

i was actually going to do this today too but i got lazy and just finished welding my exhauts.

good job though.

*edit: o s*** just noticed its a vert. i LOVE those

*edit edit: i also like the way you took the whole bumper off i would have prolly tried as hard as i could have to keep the bumper on, then after an hour or two of asking god for a break, i would just give up and drive around with holes in my bumper. (no i would have finished it)

[onosqv]

I may paint it black later - looks fine in reg aluminum to me tho.

I opted to use less rivets because I personally didn't like seeing a bunch of rivets on the bumper like other cars had. Just personal preference.

Lots of different designs I could have done, but this one was the simplest to do.

[kpariaug]

yea ive just got this thing bout flat black and silver. it looks really good tho. i dont know when i'll get round to it, maybe tomorrow