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  #191  
Old 12-18-2017, 11:17 AM
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Looks great!
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  #192  
Old 12-22-2017, 11:10 AM
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Post Engine covers (continued…)

After welding up the corner seams, it’s time to add all the detailed elements into the cover. First detail was making an opening for the breather tube and ignition coil wiring to pass through. I made a quick and dirty hammer form in a 2x4, annealed the aluminum, and hammered in a louver like opening.



The cover was then placed on the engine for a test fit. I found the supercharger intercooler coolant pipe hit on the rear upper corner.



While it wasn’t absolutely necessary to address this, I thought it would be a nice touch to indent the cover and also make a rest for the pipe to sit on. I cut out the corner and welded in a small piece of aluminum to make a notch in the cover.



Next was making holes for the spark plug wires to pass through. I could use a hole saw to do this but decided to try out another method instead. I marked a circle with a Sharpie and used a RotoZip to carve away the aluminum. It actually worked great and only required a little bit of cleanup with a file to make a smooth opening.



The 4 upper holes are for the spark plug wires and 3 lower holes are for extra ventilation. This side of the cover isn’t visible so none of these holes can be seen.



Here is the completed cover. It fits snug enough over the corners of the SOHC cam cover that I don't think it will need any fasteners to keep it in place.



I plan to paint it with red wrinkle paint like is used on early Ferrari Testarossa engines. The paint work will wait until the drivers side cover is completed. The drivers side cover will be a little more difficult given it’s got more stuff around and over it.
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  #193  
Old 12-31-2017, 01:36 AM
Gojeep Gojeep is offline
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Nice result there Joel.
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  #194  
Old 12-31-2017, 05:58 PM
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Post Engine covers – Drivers Side

While the basic forming of sheet to rectangular box for these engine covers was the same, I found a way to mess up my first attempt on the drivers side cover. Somehow I miscalculated on the sheet measurements and the cover ended up ¾” too long. Given the engine setup back, this put the cover too close to the firewall.



The cover in the back of picture is 1st attempt and destined for scrap bin. The cover in the middle is the 2nd attempt and the right size. The partial cover in front is the mockup for where the rear corner needs to be altered to provide clearance.

The C5 GTO engine bay is not all the wide and the brake fluid reservoirs are mounted on the firewall. I wanted to retain the rounded edge look even in the chopped off corner. So I added in a pie cut and rounded over the edged with a hammer and T-dolly.



Given the irregular shape, the patch piece took some careful bending and fit up work prior to welding in.



Here’s the corner after welding and metal finishing.



More to come …
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  #195  
Old 12-31-2017, 06:46 PM
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That's a pretty slick job of the corner.
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  #196  
Old 01-01-2018, 01:12 AM
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congrats on MSOTM joel well deserved
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  #197  
Old 01-01-2018, 01:27 AM
Gojeep Gojeep is offline
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Well done on the MSOTM Joel.
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  #198  
Old 01-01-2018, 02:25 AM
Paul-S Paul-S is offline
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Beautiful work!
Congratulations Joel


Greetings Paul
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  #199  
Old 01-01-2018, 05:11 AM
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Congrats Joel.

Happy New Year.
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  #200  
Old 01-01-2018, 07:46 PM
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Thumbs up Msotm

Wow what a surprise and quite the honor. What a great way to start the new year!

My first thought is to pass along a heartfelt thank you to all the people in the metal shaping community that have helped me to gain the skills to be given this honor. I've learned so much from the information and pictures you all post here and am glad I have the opportunity to put what I've learned into practice through my hobby.
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