Adding screen to front bumper ducts
 

My fog lights are full of chips and one has a hole so I’m looking at the most cost effective long-term solution and have decided on cult werks ducts. These will not be used to run cooling to the front brakes but only to the oil cooler and air-conditioner areas. Even at that I’m not sure how effective they’ll be but at any rate I like to add some kind of screening to keep rocks (the kind of break fog lights) from passing through.

I’m wondering what solutions others have done for this. I’m thinking of applying some stainless mesh but unsure how to attach it.

Thx- pete

Search on this forum. There are a couple of good write ups on what folks have done.

I went to Home Depot and got some window screen material, cut a couple of squares about an inch larger than the back of the brake duct opening, then first put an elastic band to secure the screen to the duct, then used contact glue around the edges of the screen material to hold it permanently, then removed the elastic.

Miss this guy! Babalouie was an awesome mod-Meister.
Checkout his RL threads before you start a project...

https://rennlist.com/forums/964-1989...t-install.html


His epic thread: Aussie 964C2 Maintenance Diary (pic heavy!)

https://i106.photobucket.com/albums/...che/911172.jpg

Great- thx guys. I did search a bit an found one example on pelican:

http://forums.pelicanparts.com/porsc...s-install.html

I definitely want to use a metal screen I was thinking of stainless but I have this then brass mesh laying around it’s pretty easy to bend so I tried a quick test:
https://cimg8.ibsrv.net/gimg/rennlis...db374ada3.jpeg
https://cimg2.ibsrv.net/gimg/rennlis...fccdb78ec.jpeg
https://cimg3.ibsrv.net/gimg/rennlis...1df241527.jpeg
Seems like this will be a good way to go (assuming I can find the right diameter pipe stock to match the ducts) and I’m not sure even need any glue - if anything maybe just a screw. That way if it does get torn up by a rock I can easily replace it. I figure I’ll trim the excess with a Dremel.


Are you guys using metal mesh or nylon? Are there any other materials that might be suitable?

pete

Your metal/pipe method looks good.

This might also be a good 3D printer project. Make plastic brake duct caps??

Great idea- then sell them to Cult Werks! Seriously though it would make a cool little kit and probably 90% of us using them are not routing to the brakes. In my case I’m simply using them because I think is the best long-term solution in terms of dealing with chips from rocks etc. those fog lights are damn expensive and RS dummy lenses look good but they also look like they break if you look at them funny.

Pete

First off I don't cut the opening as large as they so to. I make sure you can always remount the fog if you choose. I used a brass screen painted it black and just mounted it flat to the bumper itself covering the entire opening. I found on track when I had a screen attached to the duct only rubber and other debris made it around the sides.

Here is another option. https://rennlist.com/forums/964-foru...ml#post9959309

Vandit's thread is also a helpful resource as well.

Another photo journal, lots of misc. projects I completed over the past few months.

This sounds like a pretty ideal solution. Any photos of the size of your cutout?

This is my track car. I have a second oil cooler on the right side with lines so it gets tight back there. I will probably never put the fogs in the car but I decided it was worth keeping the sides if someone one day decides to. I am currently switching to the Cult Werks ducts. They are by far the best I have come across and their mounting approach is fantastic but requires bumper removal. I had MA Shaw before and they kept popping out when hit by rubber on track. I went with a thicker screen the thin brass screen I used before took a direct hit and the rubber put a hole through it. I cut the cult werks ducts to fit flush with the screen and it directs the majority of the air to the opening over the cooler.

I use the ducts to cool the coolers and I have them well sealed so the air is forced to flow through them. For brakes I used a nozzle from a wet vac and attached a hose below the coolers so I didn't interfere with the air flow and it was easier to cut through the plates to focus the air on the center of the rotor. It also allows additional air to flow over the oil cooler from below while capturing lot of air towards the brakes. It seems to work quite well and I have no overheating issues or fading brakes. As you can see the car gets hit with lots of rubber at high speeds and large chunks get caught everywhere.

Unfortunately the car is down for an engine rebuild and evo upright install.

https://cimg8.ibsrv.net/gimg/rennlis...c1d448b9fd.jpg
https://cimg9.ibsrv.net/gimg/rennlis...0671418c03.jpg

How I did mine. Pretty easy.

Forgot to share this thread as well...I have a set along with the rs mid section sitting in my home office unpainted. Haven’t had tome to get it painted but as you can probably tell I’ve been researching lol

Cult Werks duct install