As I've got fenderwell inlets on my car my inner fenderwells in the rear have holes\slots cut in them for the tubing to pass, air is drawn from alongside the intercooler duct. There's a decent amount of space around the piping and I'd like to seal it up better!

I'm thinking a 6x6inch piece of something pop-riveted to the hole with room just large enough for the piping would clean things up. Something flexible to allow a little movement and seal would be good. I've tried neoprene but it's so soft as to be useless. Some sort of rubber mat with cord in it maybe? I've built fenderwells on another car from plastic material that they line dump trucks with and it might work but it's not very flexible. Ideas?

I figure I'm not the only one who might benefit from a solution!

 

I think your on the right track with the dump truck liner, it's a UHMW. I have been using this in a thinner plastic, think ski/snowboard base material at 2mm, it molds really well and comes in a flat sheet. You can see how I have molded it on the sides and how it smoothly wraps under the cap. Could send you a small piece to try if you like

 

Ah, what I used before was pretty thick! I hadn't considered getting it in the thinner sheets, that's a terrific suggestion. I'll have to figure out where I got it before - excellent service and price. Subaru guys use it for mud flaps and I molded it for wheel well liners when the stock pieces no longer fit my RSTi. It's worked great and I think in a thinner piece it would work well here. Did you have to apply much heat to it? At that thickness I might be able to really form it nicely. I've got the liners back in the car and drove it today, seems most of the boost is back Easy to pull though, I still wonder if the rubber might make a better seal if I could find the finer reinforced stuff heh. Maybe the plastic and a gasket of the rubber would seal it up good and keep dirt off the filter

 

The thin pieces 2mm just take a few brushes with a propane torch, then just form it into the curve you want maybe a big bowl from the kitchen or something, then hold it there with some gloves on till it cools a bit. The thicker stuff like 3/16" I'll heat in the oven for 5-6 minutes at 350* then form into a mold. I use the thick stuff for the cap on front of the pad. The UHMW caps will last 5-10x the normal plastic that comes out of our injection molds.

 

Nice, thanks!