Abstract: A method of manufacturing a heat shield including the steps of providing a plurality of substantially uniform and equal thickness formable sheets, embossing the sheets to form standoffs, and preforming the sheets to an intermediate configuration having contours. Further, the method includes the step of cutting the preformed sheets to form a perimeter edge defining a projected area which is generally identical for each of the plurality of sheets. In addition, the method includes the steps of stacking the cut sheets, and joining the stacked sheets.

Abstract: A heat shield for providing thermal insulation is made of several uniform thickness aluminum sheets. Each sheet has stand-offs formed therein to space adjacent sheets and create air pockets in the heat shield.