I am going to try my hand at fabricating a custom ram air for a 2000 SSEi. I've been thinking this one over for a year now, and have a drawing I'd like to try to build from. Problem is, I don't know where to get my hands on materials like plastic (acrylic? Plexi?) sheeting. I was thinking of making my prototypes with foam core (the stuff you mount posters on) or matte board.

Anyone have any ideas?

Interesting subject here. The same idea is nested in the back of mind as well.

There is a company local to me here called FLN-MAR Rubber and Plastics. They primarily deal in conveyer belts and pneumatic and hydraulic hoses. In the past though, I bought some 3/16" polycarbonate for a panel saw project which I never finished. Here is their website:

http://www.flnmar.com/

Also, try local sign companies and places that make retail displays for acrylics, plexiglass and Lexan. Home Depot has some suuff the last time I checked too.

I buy my acrylic from Home Depot, and get my polycarbonate and Plexi from various suppliers around me. Glass companies also carry it.

Try an injection modling company, there are some in my area, that sounds kinda like what you are looking for. Otherwise many car audio shops make custom fiberglass sub boxes. They may be able to help in that regard too.

Yea, Home Depot has the acrylic sheet.

All you really need to do is to make sure your engine has as much of the coolest air possible...don't worry about ram air it won't help you with a supercharger.

The first thing you might want to do is check out SilverBullet'* CAI;

http://www.cardomain.com/memberpage/383040

He'* had a couple of setups with the latest one being simple and effective.

I did a custom CAI for mine which is the previous body style to yours;

http://whiteswebs.com/ssei/cai/index.htm

I highly recommend you use polycarbonate. It can easily be bent with a heat gun, you can drill and tap it or otherwise screw into it if you use 6mm (1/4") and it'* good for temperatures up to 800*F. Acrylic may still work but it'* more brittle and less forgiving besides not rated for as a high a heat.

Also, you'll want to make a complete mockup using heavy cardboard like you get from TV or fridge boxes. It'* well worth the effort to get things just right before you start cutting you material.

Cheers,