Well the small tooling holes are approx. 1/16 inch..
the others are 1/4 inch or more...

Okay I'll help out....

Some suggestions::
Possible use High Temperture Silicone automotive sealant to fill up the
holes..

Possible use aluminum tape /Ducting small pieces to cover the holes
from inside..


Well thats what I did....

Third over the top...
Paint the exterior with high temperatue paint / w/ceramic coating
to help deflect some of the engine compartment heat...


Last -- route the hose to a nice cool inlet air source.....



Well thats what I did... enjoy...

 

do you have some pics?

 

Thanks for the tips Henry, I'll be installiong mine tomorrow.

BTW, pics of your fix would be nice.

 

I didn't take any pics of the fabrication mods....

I still have another vehicle to work on..

But... I 'll get a final complete pic.... tomorrow.. possible..

 

Completed install pic..

As you see the outer surface is color coded to match the Valve cover..
(All the holes are sealed up from the inside)

Also the 3" diameter duct -- Isn't installed to the side
fender well... it's pipe down , and hook up to a Nascar air scoop type of
duct , which is position in the lower grill/inlet area as to not
to affect the radiator cooling fins...

thats it...

 

Sorry Henry, can't see your pic.

 

That's strange....it was there earlier, when I viewed this thread. Gone now !!!

 

 

Where did you get the air intake hose?

 

I'm having my intake box powder coated the same color of my HHR. I'm just waiting for them to call me when it is ready.