Locating the supercharger air intake within the passenger side front wheel arch has created a bit of an issue to ensure the air filter receives an adequate flow of air. It just so happens that my car had an air intake funnel located behind the front grille to direct air into the cabin air vent. So, I decided to re-purpose the opening.
Design & Build
This is the hole that is located by the front grille. First job was to create a template.
Next job was starting with the above template and creating a CAD model in Fusion360 which proved to be a very tricky process. Mainly getting the angles of the inlet and outlet correct. Once I was happy the design it was over to the 3D printer and 5 hours later I had a rough product that needed finishing.
I cleaned all the rough edges left by the print process (mostly caused by overhand supports) with a Dremel sanding drum. Next, I applied a thin coat of filler over the entire part.
The final step was to apply a coat of truck bed liner paint to give it a uniform and robust finish.