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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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 Posted: Wed Jun 03, 2009 4:02 pm Post subject: Making my own valve covers |
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I thought I`d just start my own thread on how to make 36hp valve covers. The first thing and the hardest part is coming up with a pattern you can`t just have an old valve cover recasted because aluminum will shrink just under a 1/4" per foot. So what i did was dig out the old wood working tools and build one from scratch. The trick is making everything bigger to make up for the shrink. And if you plan on make alot you have to make a double shrink pattern to ended up with aluminum pattern that will last. So heres the pictures.
The wood pattern.
The first casting.
After alittle polishing.
This one isn`t just right so it will become and ash tray. The holes are off alittle and it`s a bit tight on the sheet metal no room for the engine seal. Anyway I know what I need now and hope the next one will be right on. 
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splitvws
Samba Member
Joined: February 12, 2004
Posts: 142
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| Posted: Wed Jun 03, 2009 4:08 pm Post subject: |
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| Nice work! and I like the looks of the cover |
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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Towel Rail
Horizontally Opposed
Joined: April 15, 2005
Posts: 4622
Location: SE CR IA US NA PE
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| Posted: Wed Jun 03, 2009 5:27 pm Post subject: |
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Looks pretty sweet! How do you plan to true the seal area?
FWIW, they'll cool best if left rough, but then they wouldn't look as spiffy. 
- Scott
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1974 Thing -- under the knife
1967 Beetle -- spring/summer/fall driver
1996 Subaru OBW (EJ22, 5-speed, AWD) -- winter car, 3-seasons "don't feel like biking today" car
049 > 070 > 053 > 009 |
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Boonies
Samba Member
Joined: November 30, 2005
Posts: 816
Location: Chicago
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| Posted: Wed Jun 03, 2009 5:34 pm Post subject: |
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Looking good.
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splitpile
Samba's Worst Speller
Joined: May 03, 2000
Posts: 5927
Location: back to living where hell meets the suface
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| Posted: Wed Jun 03, 2009 5:53 pm Post subject: |
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Nice, are going to be selling the final versions when done?
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www.BUSTORATION.com metal and more for your bus
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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| Posted: Wed Jun 03, 2009 5:54 pm Post subject: |
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I think I`m going to make a new pattern and use most of the parts on the old one. I`ll lower the top to match the bottom for the seal fit and also adjust the top so the holes match better. This happens all the time with the first pattern and changes have to be made when its the first pattern you`ve ever made. If I would have test fitted the wood one to the motor I would have found it was tight but I didn`t want to remove the rockers and adjust the valves again so now I have to pay.
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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| Posted: Wed Jun 03, 2009 6:00 pm Post subject: |
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| splitpile wrote: |
| Nice, are going to be selling the final versions when done? |
If I can get them poured for a good price I will. Right now it`s one at a time and done by hand. I thing the owner of the foundry is just having fun with me thinking I`m crazy but when I showed up with a pattern that I made he had a funny look in his eyes.
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36hplandspeedracer
Samba Member
Joined: January 30, 2006
Posts: 847
Location: Ivins, Utah
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| Posted: Wed Jun 03, 2009 7:59 pm Post subject: |
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Looks like they are going to be real nice, as well as updated. Good luck on introducing a NEW 36hp product. We can always use more of that!
Burly |
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69 Jim
Samba Member
Joined: September 27, 2004
Posts: 6264
Location: Chickengeorge's Neighbor
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| Posted: Mon Jun 08, 2009 7:04 pm Post subject: |
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| You sir, are a craftsman. Nice work. |
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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| Posted: Tue Jun 09, 2009 6:13 pm Post subject: |
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| 69 Jim wrote: |
| You sir, are a craftsman. Nice work. |
Thanks,
But its not as hard as it looks. I was hoping to make up a new one last weekend but got side tracked with other things the wife needed. Anyway I did pickup the needed wood and should have the new and approved model made soon. If I get everything right and can get them poured it`s looking like about $150.00 a set for now(thats one at a time ). But my goal is to have 3 to 4 poured at the same time lowering the price but not polished. Anyway the cost has been all on me so far and when I finish with my maddest it souldbe as good if not better then the older vintage covers. Give me a week and I should have a new pour.
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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| Posted: Fri Jun 19, 2009 8:28 pm Post subject: |
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Update. Well I just finish the new pattern and resized and made all the adjustments to fix the problems with the first one. The first of next week I`ll have it poured and hope it will be right on. This one is thinner and alittle lower to give room for the engine seal and should also be lighter as far as weight. The old one was very heavy.
Have a look and I will get it right .
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a-train
Samba Member
Joined: October 11, 2003
Posts: 702
Location: Issaquah via Parkland, WA
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| Posted: Sat Jun 20, 2009 3:02 am Post subject: |
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very nice, excellent craftsmanship.
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chivoragtop1959
Samba Member
Joined: February 07, 2005
Posts: 25
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| Posted: Sat Jun 20, 2009 9:11 am Post subject: |
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ALUMINUM AS 3 PERCENT SHRINKAGE
MOLD MAKER
TOOL AND DIE
GLENDALE CALI |
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engineerscott
Samba Member
Joined: August 22, 2005
Posts: 455
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| Posted: Sun Jun 21, 2009 8:03 pm Post subject: |
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Are you planning on doing some machining of the surface where the valve cover interfaces with the gasket? I'm afraid that without a flat, smooth surface you are going to have issues with oil leakage around the valve cover gasket. If you have access to the facilities I'd make a jig to hold the cover and then use a CNC endmill to machine that surface.
Don't take this a criticism BTW - You've done some remarkable craftsmanship that most people only think about. Excellent work. |
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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| Posted: Wed Jun 24, 2009 2:18 pm Post subject: |
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Update, Got the new and improved casting of the second pattern back today. Yesterday they poured one but it came out bad so today they repoured it hotter and it came out good but rougher from the heat. It needs alot of cleanup where some of the corners broke off from hand packing the sand and not using a air ram on it. The wood pattern is somewhat fragile and care has to be taken or it could break. Anyway the shrink came out just right very pleased and after fully polishing this one inside and out it will be the main pattern for making many more. I`ll post more pictures after I get it polished up.
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Louis
Samba Member
Joined: September 26, 2007
Posts: 423
Location: canada BC
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| Posted: Wed Jun 24, 2009 2:20 pm Post subject: |
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wow impressive work with out cnc!! old school, pure essence of vintage speed...
cheers |
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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faster
Samba Member
Joined: September 25, 2005
Posts: 1386
Location: Ga.
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| Posted: Wed Jun 24, 2009 5:33 pm Post subject: |
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Well I had to see how it fit so after alittle polishing on it went. Very pleased the seal has plenty of room it looks like its touching in the picture but its not. Now I have to finish polishing the rest of it and back to the foundry.
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splitpile
Samba's Worst Speller
Joined: May 03, 2000
Posts: 5927
Location: back to living where hell meets the suface
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| Posted: Mon Jul 06, 2009 11:12 pm Post subject: |
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| faster wrote: |
Well I had to see how it fit so after alittle polishing on it went. Very pleased the seal has plenty of room it looks like its touching in the picture but its not. Now I have to finish polishing the rest of it and back to the foundry.
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Any more progress?
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Stocking distributor of "The Funky Green Panels"
www.BUSTORATION.com metal and more for your bus
"no more hacking my sig line" |
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