Cutting S3 engine cover to fit with Revo CAI - with pictures

StuartG · Feb 8, 2018

I thought I would just share a few different pictures to help others save time figuring out the cut lines if they want to keep the std S3 engine cover when fitting a revo CAI. The open section on the rhs can be closed by plastic welding a section of the flat plastic you have cut off. Hope its useful to others. Stuart

mechanic69 · Feb 8, 2018

Good job, prefer the tts cover solution though, gives people options

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S369pete · Feb 28, 2019

Hi there Im just about to do this mod too and was wondering what tools you used to cut the cover. Managed to pick a cover up for 20 quid yesterday so I'm ready to start cutting.

StuartG · Mar 1, 2019

I used a thin slitting disc in a 4.5" angle grinder for cuts and then heat gun / soldering iron to close the area in 3rd picture using a discarded offcut and plastic welding. HTH Stuart

prt57 · Mar 1, 2019

Whilst it is a more expensive solution, the TTS cover does look good with the Revo pipe. No more wrestling with those awful mounting grommets either!

S369pete · Mar 1, 2019

Thanks for the advise as I don't have an angle grinder to hand I decided to buy a draper tool for the job. Done a little cut on the box and it slices through like a surgeons blade so this will work well. Didn't actually come with any cutting blades but lucky I had some lying around.
Same with every mod I do I seem to spend more on tools than the actual part lol. Draper was 28 quid cover was 20 quid.
I think I'm gonna play around with the finish too. Will post up results

Cutting S3 engine cover to fit with Revo CAI - with pictures

StuartG

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mechanic69

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S369pete

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StuartG

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prt57

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S369pete

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