Topic: How To: Modify OEM heatshield for aftermarket downpipe

[snackers]

The stock turbo heatshields will not fit around a big aftermarket bellmouth downpipe.
Some people don't like blingy aftermarket heatshields. They're all shiny and say "LOOK AT ME!! I'M AWESOME" and may possibly distract your attention away from the NOS button.

...and I'm just cheap, so that's my excuse.

Here is how to modify your stock heatshield to accommodate a big downpipe.

Tools needed:
Dremel or angle grinder
Cutting disks (maybe 2) or cutting wheel
Sanding wheel (dremel only, cutting wheel works for multiple tasks on an angle grinder)

We'll start in this general area here.



Cut this sort of shape into the heatshield.
It took me a couple tries to make it big enough for clearance.
Don't get too close to that bolt hole. If that snaps, you'll probably get some annoying rattles.



I used almost a whole cutting disk for this.



Verify your fitment.
Yes, the bolt on the right side looks close, but the shield is just resting on the turbo. It will shift about 1/2" to the right when bolted in.



It may take you more than one attempt, or you may get it right the first time.

Use the sanding wheel (or cutting wheel on grinder) to clean up the cut so that you don't slice your arteries open when you take the shield off in the future.



Clean up the edges.



Install shield.



There should be 4 heatshield bolts to use.
2 under the TMIC, 1 on the rear (firewall) and one way down at the bottom holding the shield to the turbo bracket.

Bonus of being cheap?
You are now "sleeper".

[GrantC]

Baller! I think I've always done it with tinsnips & a file.

BTW, if you're extra lazy (and not modding to the minimum required for a certain set of rules *cough* ST legal auto-x *cough*) then the Cobb instructions show you can also trim that entire right hand side off and not have to deal with that lower bolt.

[snackers]

I read that as well, and have seen many threads where people just pop the welds and remove that lower piece.
However, that removes shielding between the turbo and the power steering lines.

I chose this route to keep those hoses shielded.

[silverSTi]

I just wanted to say how much of an awesome write up this is. It is complete from A-Z without any questions. I did this in the summer and I have had no issues since.