I printed the detailed drawings for the OSM off of the stickys and took them to several metal shops around here, and after I recovered from sticker shock, $125 - $155 for 14 gauge metal, I was wondering where you guys that have them got them and how much they cost?

 

I made mine at work out of 18ga steel. there is NO WAY it should cost more than 50 bucks! And thats including metal! If its because of the bends is why it costs so much, cut and weld it together to save if you have access to a welder. It took me maybe 1/2 hr tops to make my mount. And i did bend mine. very simple.
hope it helps.
ez

 

That is pricey! I wish I could have made mine within 30 mins. Took me a few hours atleast. But it is fully TIG welded 16ga aluminum diamond plate .

 

I picked up the heaviest gauge metal i could cut by hand from Tractor Supply, used a pair of tin-shears to make the cuts and made teh bends over the edge of my work bench..mounted it using self-tapping screws.
Think I have about $18 invested in it....

I need to paint it, but its working fine for over a year now.......

 

Thats what iam talkin about... find a way to do it yerself! Thats what is great about these first gens, aftermarket dosen't hardly recognize us so we find a way!!!

 

i had some free diamond plate. i cut it myself and including the 5inch hole with a hole saw. i had them bent, (2 of them) i believe i paid $25-35 to have them bent, they wanted $50 to cut the holes.

 

I used a one lb coffee can for a template and then the tin snips for most of it... then realize the metal blade on my jig-saw would have worked easier( Doh!)...

The only problem I have with mine is that it is flexible enough that the bottom edge is scratching the inner fender well..

 

Mine i made from a link to this website of a pic of a cardboard template. It is not mounted with any screws and it stays put perfectly! Did have to take out the coolant bottle and move the AC drier to get it in place, reinstalled them and works fine.

 

I found a piece of scrap metal laying around, cut it with a cutoff wheel, and bent it over the workbench... I even cut the hole with a cutoff wheel because we don't have a big enough holesaw.

 

Open up your phone book and look up your local Sheet Metal Workers Apprenticeship Training Center. Most will fabricate and bend yours up for free, and the layout practice will benefit a 1st period apprentice. Purchase your metal elsewhere, or ask them to refer you to one of their local contractors specializing in Industrial type of sheet metal work. Maybe they (contractors) have some diamond plate sitting around left over from a job they finished, or ask them for Stainless Steel, at least 16 gage. 14 gage sounds overkill from the quote you got, especially if you have mounting points that will keep the box sturdy and intact. You could actually get by with a lighter guage such as 18, but then I would tell the apprentice to roll some stiffenning beads or cross kicks on the fitting. I don't believe filter manufacturers such as AFE or K&N make their shrouds less than 18 guage, and I am suggesting 1 guage thicker. Think about it. Most exhaust pipe manufacturere's use 16 guage mandrel bent aluminized. 16 guage is plenty my friend. If you do choose Stainless Steel, what would look cool is mirror finish, but maybe that might blind you everytime you open your hood!! I hope my advice helped. Oh yeah, keep in mind that all metal, I mean all kinds, stainless, copper, galvanized, etc. is overly expensive anymore, due to the war. Expect at least $50.00 for a hunk of steel for the BHAF box dimensions.

 

I was going to use 16ga but we didnot have any scrap of it at work and i thought pulling out a new sheet was a little conspicuous! haha 18ga works great in my opinion. Bead rolls would look awesome on ole' smokey mount!

 

i just cut out most of my airbox and am about to get a k&n it should be awesome!

 

I have access to some scrap diamond plate aluminum, probably cheap. I can ask how much I could buy if closer members would be interested.

Daniel