Hot Rattles

Some time ago, my Mitsubishi Evolution vehicle developed an unsettling rattling noise, which many automotive enthusiasts would recognize as the distinct sound of a heat shield vibration. However, it's worth noting that the car no longer had its factory exhaust system, and aside from a custom-made heat shield surrounding the turbo, there were no other heat shields installed. After conducting a thorough investigation, my father and I identified that two out of the three tabs responsible for securing the heat shield had fractured at their weld points. The decision to employ three separate tabs in the design seemed, in my view, to be a potential weak link in the system, and unfortunately, it proved to be one.

In response to this issue, I resolved to design a single-piece bracket as a solution. Preferring not to dismantle the entire assembly, I embarked on an innovative approach. I carefully removed the brackets from the turbo side, introduced nickel coins as spacers beneath the bracket, and repositioned the damaged segments of the tabs. Subsequently, I scanned the assembly using the Polycam application on my iPhone.

The quality of the scan results, while acceptable, required refinement, and by utilizing point-to-point measurements with a caliper, I constructed a model for the envisioned replacement bracket. However, it's worth noting that the scaling of the scanned mesh, when imported into Fusion360, displayed a significant discrepancy. Consequently, I dedicated considerable effort to redesigning and scaling the model to maintain accurate proportions. After the model was crafted from 316 stainless steel and subsequently cut, some minor hole adjustments were necessary to ensure a proper fit on the turbo side. The assembly is now complete, and it exhibits remarkable robustness. It is my belief that any concerns pertaining to rattling noises emanating from this specific area have been effectively mitigated for the foreseeable future.