The Air Duct/Bellows has a know design defect. It collapses a bit under hard acceleration when the engine compartment is hot. This is also curable by purchasing a new and improved Samco air duct made of silicone. This article presents a way of making your own. The whole procedure took about 1.5 hrs. Not including the time I waited while heating up the plastic bellow in my oven at 175 deg for 20 min.
Start by finding a piece of aluminum sheet stock of at least 9x20 and 3/16 in thick. You also need to remove the bellows and the air horn. The air horn is needed to act as a template form factor to bend the metal around.
What is not shown here is the metal wire form that I used to know where to make the bends in the sheet metal. Sorry about that. I forgot to take a picture of it. Using a piece of chain link fence post I bent the initial form to match the wire form.
The metal form is shown here roughed in and ready for fine tuning.
This is going to be hard to explain. Note the vise grips. They are there to hold the sheet metal as I drive the base of the form with the big vise head. This puts a bend in the flat portion of the sheet metal.
By forcing the pipe in after clamping the metal form in the vise, I get closer to the shape I want. Thing to do now is pound down on the protruding metal to shape the top.
I ended up bending the center down too far so I used the "big pipe" to force it up.
We're almost there. Now it is time to get the form inside the duct.
Here you can see that the form is just the right size.
The plastic bellows was put in my oven at 175 deg for 20 min. then the form was slid into it. Fits like a glove.
Here I am tightening up the fit by opening up the form inside a bit. Nice tight fit.
The strength of the form inside the bellows needs all the leverage shown her to get it to bend out a bit. All done now just have to mount it in.
 Author: Scott Fabre
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