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1994 del Sol S
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1,103 Posts
Discussion Starter #1
Since I kept blowing Aux light bulbs, I stopped using them on a daily basis. I figured why leave them in there, if they aren't going to be functional? I've always wanted to make an 'air duct' to the air filter, and this would be the perfect opportunity to do so. First, I'll start with the grill/mesh. I haven't done the actual duct yet, but I'll be working on this this weekend most likely. Stay tuned for that.



Materials Needed:

Gutter Guard or Any Mesh of Your Choosing (Gutter Guard is $4/roll at Lowes for the black plastic kind. They were out of the metal kind, and I figured the plastic kind was already black which was the color I wanted)
Wire Cutter (Or scissors or anything to cut/trim the mesh)
Ratchet and 10mm socket with extension
Phillips screw driver
Time Needed: 30 Minutes to 1 Hour (Depending on how fast you work)


1) First off, you're going to want to unplug your Aux lights from the harness. I didn't take a picture of the plug and it's location, but if you can't figure this first step out, doing the rest of this probably isn't a good idea. Once they're unplugged, start removing your bumper. There's a few 10mm bolts on top of the radiator support, and screws up in the fender well. You don't HAVE to remove your bumper...I didn't.

2) Unbolt your Aux lights (the only bolts you should have left is the big rounded Philips screw/bolt on top of the radiator support, and the one that's recessed down next to the headlights.

3)Once the Aux light unit is fully unbolted and unplugged, pull the upper part of your bumper back and wiggle out the unit (if done right, it will come out). Once removed, flip it over and look at the back side. You'll see this...


4) Remove the 2 screws holding the light to the bracket, and squeeze the little black square clip and push it through the hole. Now it should be held in only by ball/socket type of thing (I honestly don't know what to call this... It lets the light rotate when you're aiming them). Wiggle the light itself, and with some force, it'll pop out and be in your hand.


5)Now, you have an empty bracket in which you can secure your˙mesh to. You can either re-use two of the original bolts and source 2 more, or just find 4 new/different ones. I used the 2 original and found 2 more laying around the garage. Measure your mesh out to the length of the bracket, from TOP to BOTTOM. Before you cut it, add another 2" or so. There's a reason for this...

6) Once your mesh is cut, secure it to the bracket with the screws with the excess hanging on the bottom part of the bracket.


7)When you go to re-install your bracket, wiggle it in there so the excess mesh on the bottom sits between the bumper itself, and the frame of the car. The reason for the excess mesh is so it covers the entire hole in the bumper. If you cut it to fit to JUST the bottom of the bracket, you'll have a small gap.

Put everything back together, and bam. You now have grill mesh which will let cooler air into the engine bay.





NOW, the only draw back to this, is there is a small gap on the outer side of the mesh/hole (on the headlight side). The gap is maybe an inch wide, but where it's at, I'm honestly not TOO worried about it. I'm still working on ideas to make this gap disappear.

 

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ministry of mayhem!
93 honda integra
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5,673 Posts
looks kinda decent, but if i were you i would just chase the short... voilà, aux lights back.

EDIT: a real nice idea for a air duct like you're planning to fab.

2ND EDIT: i would do one side, and leave the other one with the aux light assy. and then i would fab a intake pipe with a velocity stack that would rest right behind the open side.
 

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08 H-D Ultra Classic
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Looks good man good write up! What are you going to use for ducting and where are you going to duct it to?
 

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1994 del Sol S
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Discussion Starter #4
looks kinda decent, but if i were you i would just chase the short... voilà, aux lights back.

EDIT: a real nice idea for a air duct like you're planning to fab.

2ND EDIT: i would do one side, and leave the other one with the aux light assy. and then i would fab a intake pipe with a velocity stack that would rest right behind the open side.
Not a short, I dont think. They would work for about 2 weeks then randomly blow. And only on the drivers side. Got sick of replacing them, and since I really didnt use them to begin with...easier to just pull 'em.

Looks good man good write up! What are you going to use for ducting and where are you going to duct it to?
I was thinking just plain plexiglass. Easy to work with, and stupid cheap. I'd have enough 'glass to make an entire duct for less than $20. I'm going to route it right infront of the air filter (short ram intake). It would save me from putting my filter in the wheel well.
 

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129 Posts
Looks ok but i would just get blockoff plates painted black or a velocity stack and intake pipe run through
 

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1994 del Sol S
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Discussion Starter #7 (Edited)
The only way you're fitting an intake pipe from one of the grill openings, is if it's literally 2" big. There's not THAT much room between the headlight and radiator. Maybe as an air duct to the regular intake, yes. But not as a legit intake to the engine.
 

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duh
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883 Posts
I looked into this as an option over my Sig Pic as I never use my aux. lights either
But didn't like the look. Good work tho dude!!
 

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What would be sick is a front mount turbo using the Aux hole as the opening for the turbo. Nice little DIY though... Hey can i have you aux pigtails? Thats all i'm missing on my sol. I sold my yellow aux's about a year back and didnt think twice before selling the pigtail with it lol
 

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1994 del Sol S
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Discussion Starter #11
I looked into this as an option over my Sig Pic as I never use my aux. lights either
But didn't like the look. Good work tho dude!!
As in the huge filter where the headlight normally sits? IDK about laws where you live, but here in NY, we're legally supposed to have working headlights on our cars. lol

What would be sick is a front mount turbo using the Aux hole as the opening for the turbo. Nice little DIY though... Hey can i have you aux pigtails? Thats all i'm missing on my sol. I sold my yellow aux's about a year back and didnt think twice before selling the pigtail with it lol
Which pigtails? Of the lights or off the harness in the engine bay? I'm not about to just cut the pigtails off a good, working set of Aux lights...lol
 

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duh
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As in the huge filter where the headlight normally sits? IDK about laws where you live, but here in NY, we're legally supposed to have working headlights on our cars. lol
haha, Yeah. =]
I only drove home from the track like that, about 10 miles, during the day.
 

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I never made you your set...
Looks like you got motivated and did work. Hah!

I've been running these since '09 and they cool the air under the hood big time.
 

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ministry of mayhem!
93 honda integra
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5,673 Posts
I never made you your set...
Looks like you got motivated and did work. Hah!

I've been running these since '09 and they cool the air under the hood big time.


oh now i remember. i had this burning question but yes it was you who showed me that back in 09.
 

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1994 del Sol S
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Discussion Starter #15
I never made you your set...
Looks like you got motivated and did work. Hah!

I've been running these since '09 and they cool the air under the hood big time.
Dude, you aren't kidding! My water temp gauge when driving is 2 ticks on the gauge lower than normal. Actually helped lean out my A/F's just a hair, too! I'm going to TRY and get a duct made this week if the rain holds off. I'll hit you up on txt!
 

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duh
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Dude, you aren't kidding! My water temp gauge when driving is 2 ticks on the gauge lower than normal. Actually helped lean out my A/F's just a hair, too!
Shouldn't your water temp always be about 195f?...
Controlled by the thermostat..
 
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