Heat Shields for Exhaust Manifold and Turbo

In an attempt to reduce the heat from the exhaust parts being transferred to the intake piping above it (as well as other engine bay components), I previously had the exhaust manifold ceramic coated and then made a heat shield for the manifold from 0.8mm steel sheet. In terms of heat transmission I figured that the steel shield would just become a source for radiant heat once itself quickly heats up so I have ditched it and remade it using heat shield material.

The benefit of using proper heat shield material is that it has an insulating material (often ceramic) placed in the middle of the two thin pieces of aluminium sheet to reduce the transmission of the heat through the material, as well as being reflective. Despite being heavily embossed, the material is quite workable with a hammer/dolly, pliers etc and can be cut using a grinder disc or tin snips. I held bent and other pieces together using pop rivets, and washers were used with the rivets so it didn't pull through the material.

Old steel shield and new heat shield :

In addition to the exhaust manifold shield I also wanted to make a heat shield for the turbo. Unlike the exhaust manifold, the turbo housing is not ceramic coated and I wanted something much better than the tiny factory turbo shield. I mocked up a design using cardboard to cover the entire turbo exhaust housing and the first part of the dump pipe, using two factory bolt holes to mount the shield. I then replicated it using the heat shield material, being careful not to foul against the wastegate actuator rod and other components. It was a slow process and trying not to bend incorrect pieces or cut away material that I needed, the two pieces took a lengthy 6 hours to complete!

Turbo shield design :


Both pieces bolted on :