Kydex?

I need to build a shroud from the opening in the grille in my car up to the intercooler so the air has to go through instead of around it. I was thinking kydex may be good for this? Where would I get a sheet and how hard is it to work with?

It's easy to work with. I order it from www.knifekits.com

http://ascententerprisesllc.com/visionary/

They should be able to hook you up with some.

how big would the panels need to be? You can prob get aluminum in bigger sheets. rivets and thin sheet aluminum might be easier to cut and fab with.

Kydex isn't awful to work with but there is definitely a learning curve. You mentioned using it to route air to anintercooler- I don't think kydex is going to be a good choice for that application. Since it's a thermoplastic it gets malleable above a certain temperature and loses the shape you created it in. While you're driving down the road it with fresh air flowing over it there's little issue but when you're stopped and the intercooler heat soaks, engine air is heating all around and hot pavement is radiating, the kydex will lose whatever shape you've created. I've had customers leave kydex holsters in the car on summer days and the holsters have been cooked, temps around an engine bay will be much higher.
I would use carbon fiber, fiberglass or aluminum before kydex for this application.

I bought a couple 12 inch by 24 inch sheets from tandy leather in colorado springs for shell holders for the pikes peak shotgun challenge in may. If you want to give it a shot, they have them for about $20 and larger sheets I believe. but like the above poster, underhood temps might be a bit much for kydex.maybe cover it in header wrap.[Dunno]

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Originally Posted by nogaroheli

Kydex isn't awful to work with but there is definitely a learning curve. You mentioned using it to route air to anintercooler- I don't think kydex is going to be a good choice for that application. Since it's a thermoplastic it gets malleable above a certain temperature and loses the shape you created it in. While you're driving down the road it with fresh air flowing over it there's little issue but when you're stopped and the intercooler heat soaks, engine air is heating all around and hot pavement is radiating, the kydex will lose whatever shape you've created. I've had customers leave kydex holsters in the car on summer days and the holsters have been cooked, temps around an engine bay will be much higher.
I would use carbon fiber, fiberglass or aluminum before kydex for this application.

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This. IMHO, sheet aluminum will be the easiest material for your to work with for this application.

Above 400˚, kydex can produce hydrochloric gases.

I've made holsters from Kydex purchased form Amazon. I'd be concerned that on a hot day if not moving the radiant engine / intercooler heat may soften it and cause it to lose it's shape.

Shoot me a pm. I can cut you one with my plasma table out of aluminum or mild sheet for not much $$.