So after seeing what these air diffusers where selling for both on ebay and at other online retailers I decided it must be too easy to make some myself for way less. Turns out I was right. $7 and 40 minutes later they are on my xB. Im thinking about making these available to people for about $20 shipped without paint. My time is worth money. Or, you can make them yourself like this....


DISCLAIMER: If you mess up your car its not my fault. Deal with it....

Materials:

1. 48" piece of white vinyl gutter cover from Lowe's, Home Depot, wherever....

--make sure this is the solid cover and not one with holes in it.
This material is about 9mils thick. A 48" piece is enough to
make 3 pieces so you can mess one up. Cost - $4.97

2. Heavy duty scissors i.e. kitchen/butcher scissors

3. 1/4" wide double sided 3M molding tape

4. 2 - 6" x 20" pieces of cardboard

5. Pencil

6. Bench sander or belt sander - I used a belt sander

7. Drill and bits


Instructions...

1. Pop your hood. Sorry....

2. Lay a piece of the cardboard over the hole where the air diffuser goes. I suggest doing the driver side first cause its easier. Obviously it wont fit correctly. First you'll want to get the back of the template to fit against the front engine bay cross-member. Use your pencil and sketch in where you have to trim the template to fit around the hood latch. Remember, leave more cardboard than you think you need the first time. You can always trim more but you cant add it back. Trim the cardboard to fit. Once you get the template to fit flush against the cross-member, on the bottom of the cardboard take your pencil and trace the front edge of your grill. Trim this excess off. Now just trim the outside of your template to fit the width and you have your cardboard template done.

3. Do the same as step #2 for the other side.

4. Take your cardboard templates and trace them onto the vinyl.

5. Use the heavy scissors to cut out the vinyl diffusers. Make sure you leave more than you need when cutting. Again, you can trim but you cant add the material!

6. Take your vinyl diffusers back to the car and test fit. I promise you they wont fit perfect the first time. Mark them where you will need to trim.

7. Use the sander to sand down the edges and help trim for perfect fitment. Be careful while sanding. A belt sander will eat right through this light vinyl very quickly! Continue trimming and fitting until its right. It took me about 3 trims to get it right. Once the fitment is right mark on the ends where you will need to drill your mounting holes.

8. Once you get the fitment perfect its time to drill the holes for mounting. I forget what size bit I used but its obvious. Just grab the right size. Place your diffuser onto another piece of wood you can drill into. Do not try and drill just through the vinyl. You will shred it. Drill out your hole at a very low speed!



I hate being at work! Im almost done but I have to finish this DIY with the pics later....

 

Stupid question: What is vinly gutter cover? And please add some pictures when you get the chance.

 

Once I add the pics it will all be clear. I just ran out of time this morning when it was slow to finish this write-up...

 

how about sending me the part you owe me, or send me my money back.