The original factory undershield just does not work for me. I have an Evo 9, with a different intercooler, different engine/chassis brace, larger downpipe and wastegate dump. Too many things had needed to be changed on my original undertray and it's been changed up so many times. I got a new tig welder machine and I've always been scared of really thin tig welding on aluminum, so I figured why not learn and build a replacement undershield?

I started by trying to make a template. I used some old fiberboard left over from working in my basement! Lucky I just bought this transmission jack for a honda project I was working on. This would have been impossible without it.



This is the basement paneling with the shape of the original factory shield traced onto it with a pen







Once I had the shape I wanted, I bought some .050" (1.29mm) aluminum.




I traced out the shape again, and began cutting. Holes were drilled to allow attachment to the original spots on the front fascia, and the wheel splash shields




Now, the evo has a spot on the core-support that is higher than the front fascia mounting points. I needed to make little brackets and tig weld them to the shield. First I had to practice on the thin aluminum to get my welder settings right. I know it is not perfect by any means, but I am getting better!



90 amps AC triangle wave, 250hz with a foot pedal, 28 % cleaning




here you can see i installed the little brackets on the core support. I put white latex paint on the feet so it would mark the right spot for where they needed to be welded







here are the paint marks that the brackets made, so i can tack weld them in spots and check the fit


little tacks are there just to double check that it fits right. if something does not line up, I can cut these welds easier



I added more brackets in the corners near the tires so I could hold the wheel housings from blowing back into the tire at higher speeds





I needed to cut access holes to be able to install/remove the push pins where the core support is


I want to put a little "lip" on the bottom like the factory one, maybe I'll use this lip I found in the garden section of menards. I have not gotten further than this yet.

 

Hi, It would be great if you had some digital support so I can cut one for my evo I have the same problems as you with the pipes and exhaust

 

Well- I have no way of scanning it without bringing it to work (which we do have a massive 3d point cloud scanner) but it is way to big a part to bring in and it would attract too much attention.

 

edit: double post sorry

 

If you can post a picture of the outline and tell me the length of one line then I can reverse engineer it. This will probably take me like 15 mins. The line length being the most important piece of information. When I am done I will upload the dxf here so others can send it to a laser cutting service to get it cut out and shipped to them.

 

That would be great, imagine making the same part on the other side of the globe