I didn't even know this thread was still active lol. I haven't had any water issues with having mine through the side of the grill. My first scoop was plastic and decided that in the nice heat of going through Arizona and Texas it would get brittle and deposit itself into the filter. Already have the 1/16" sheet aluminum to make a good quality one, just hasn't hit the top of the priority list yet, probably when I get back from the run for the wall in June I'll get it knocked out for y'all, cardboard template it's already made and ready

I've had zero water issues in the snow/rain whatever...

The OEM filter uses synthetic media so rain water isn't too big an issue. Sucking it down like a Big Gulp WILL cause issues.

Having second thoughts on the aluminum, primarily based upon my TIG skills...or lack there-of. What do you guys think about me using plexiglass? Think it'll hold up to the wind forces?

Whats wrong with the stock system? Its one of the best air filter systems ever installed on any vehicle. Seriously.
I dislike International engines and Fords, but the 6.0's air filter system is one of the best. Period.

If you have the aluminum allready cut maybe you could get some small aluminum angle to put in corners and just pop rivit together, should be able to get it at home Depot or almost any hardware store.

We aren't saying anything about swapping out the filter or intake, look up Zoodad on Google pictures.

And bob, I only have the sheet metal, nothing is cut except the cardboard templates

What's wrong with the stock system!?!
1. Trying to suck air through that joke of a hole in the front of the airbox. Taking off that front snorkle gained back some of the MPG that I lost going to 35s. DUH! It could breathe!
2. $73 (my local OReilly Auto Parts price) for a ONE TIME USE Motorcraft filter. I paid $75 for my AiRaid drop in filter almost 6 years ago!

Other than those issues, it's not a bad piece.

So, you got rid of a high quality filter that should last 2+ years in normal conditions, filters better than any other filter on the market and flows more air than that joke AiRaid "filter"?
For what, an AiRaid that filters like crap, plugs up in 1/8th the time and flows half of what the old filter did?
Where was the benefit again? Is $75 really that much of a strain on your budget? How did you afford the truck in the first place then?

I should have read your information closer before I entered an intellectual debate with an unarmed opponent. Take your Ford hating GMC driving self back to your side of the street and mind your own business. I wouldn't have even wasted my time had I seen that piece of information.

If its not Dodge guys sticking their noses into our business, it's GM guys. :fu2: