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GDI Engine Cover progress. #391495
08/09/16 08:58 PM
08/09/16 08:58 PM
Joined: Dec 2008
Posts: 17,949
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,949
South Yorkshire
Well I've managed to get on with it, despite limited time this week. We're off to Cornwall on Saturday so given the forecast I would like to get it finished and fitted tomorrow.

So first a cardboard template, because the dipstick and oil filler need holes............





These are the trial fit holes, which will be enlarged and edged with round section neoprene to keep the water out.



Bending in progress:



Test fit with cardboard legs. This side will slot into the inlet manifold where there are two handy slots:



Now aluminium legs edged with neoprene:



On the exhaust side will be two legs. Here's the start.This would be impossible without decent snips.





The one on the right is shaped for clearance.



Pillars in place. The one on the right uses a spare threaded hole so was easy enough. The one on the left was problematical. This is the location of the engine lifting eye, but this has a tab to the rear to keep it vertical. Fitting the eye over the pillar meant cutting the pillar to accommodate this tab. Fitting over the eye meant spreading the turned edge and spacing the pillar too far over. So in the end I reshaped it back to straight and removed the lifting eye into safe storage.





This is the final test fit tonight. To locate the drilling points I stuck some masking tape under the shield, used black marker pen on the end of the studs, and touched the two, leaving a mark. The shield is slightly higher at this side.



So tomorrow, all I have to do is enlarge the holes, and edge them, and edge the whole thing.
Here is my recent delivery from COH Baines, purveyor of neoprene sections. They now have an 'order on line' facility so no more e-mail & telephone calls. Check their website for a neoprene addicts dream catalogue..........



Hopefully I'll have time to finish off tomorrow. thumbs




DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
Re: GDI Engine Cover progress. [Re: DaveW] #391503
08/09/16 09:17 PM
08/09/16 09:17 PM
Joined: Apr 2014
Posts: 3,121
Dorset, UK
milligoon Offline
Talk Morgan Addict
milligoon  Offline
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Joined: Apr 2014
Posts: 3,121
Dorset, UK
Paint it or anodised it black Dave, so it loses heat quicker.


Mark - No Longer driving
Archie the Old English Sheep Mog...........
2010 Roadster 3.0 V6 (S3) wink
Re: GDI Engine Cover progress. [Re: DaveW] #391505
08/09/16 09:25 PM
08/09/16 09:25 PM
Joined: Dec 2008
Posts: 17,949
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,949
South Yorkshire
I might do the underside black Mark, but I doubt I'll have time tomorrow.
It wasn't a problem on the Duratec even silver both sides, as there's plenty of airflow.


DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
Re: GDI Engine Cover progress. [Re: DaveW] #391518
08/09/16 10:36 PM
08/09/16 10:36 PM
Joined: Jan 2012
Posts: 14,976
Perth, WA, Australia
Richard - Aus Offline
Member of the Inner Circle
Richard - Aus  Offline
Member of the Inner Circle

Joined: Jan 2012
Posts: 14,976
Perth, WA, Australia
Top work as ever Dave.


Richard
1976 4/4 4 Seater
Re: GDI Engine Cover progress. [Re: DaveW] #391524
08/09/16 10:48 PM
08/09/16 10:48 PM
Joined: Feb 2012
Posts: 5,443
Taunton
deano Offline
Charter Member
deano  Offline
Charter Member

Joined: Feb 2012
Posts: 5,443
Taunton
That looks a good job Dave. Fiddly and time consuming but the end product is worth the effort.


Martin (Deano)
Re: GDI Engine Cover progress. [Re: DaveW] #391534
09/09/16 01:38 AM
09/09/16 01:38 AM
Joined: Nov 2011
Posts: 2,951
Australia - NSW Mid North Coas...
OZ 4/4 Offline
Talk Morgan Expert
OZ 4/4  Offline
Talk Morgan Expert

Joined: Nov 2011
Posts: 2,951
Australia - NSW Mid North Coas...
More great work from DaveW. guru


A Morgan Identified Fastidious Owner...
2011 4/4 Bespoke, 1981 Delorean, 1936 Auburn Boat Tail
Re: GDI Engine Cover progress. [Re: DaveW] #391581
09/09/16 08:12 AM
09/09/16 08:12 AM
Joined: Jul 2014
Posts: 1,316
Newcastle Upon Tyne
James B W Offline
Has a lot to Say!
James B W  Offline
Has a lot to Say!

Joined: Jul 2014
Posts: 1,316
Newcastle Upon Tyne
excellent workmanship Dave thumbs

Maybe you should be speaking with Cain re. a production run..... innocent

James


Aero8 , Series 1 - Boston Green
Range Rover Evoque S
Smart Brabus Convertible
Re: GDI Engine Cover progress. [Re: ] #391599
09/09/16 09:55 AM
09/09/16 09:55 AM
Joined: Dec 2008
Posts: 17,949
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,949
South Yorkshire
Originally Posted By PerryP
Looking good Dave.

In all seriousness, it would be great to have a list of what neoprene you use where or perhaps for key areas I.e thickness for under bonnet, door protection etc.


Start here Perry...........
http://www.talkmorgan.com/ubbthreads.php/topics/35415/Dave_s_Guide_to_closed_cell_Ne#Post35415


DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
Re: GDI Engine Cover progress. [Re: DaveW] #391631
09/09/16 12:35 PM
09/09/16 12:35 PM
Joined: Aug 2013
Posts: 11,790
Salisbury, UK
Peter J Offline
Formerly known as Aldermog
Peter J  Offline
Formerly known as Aldermog
Member of the Inner Circle

Joined: Aug 2013
Posts: 11,790
Salisbury, UK
As ever, when it comes to your projects I'm slightly at a loss for words...
Quality workmanship and attention to detail.
Well done, Dave!

As an amusing side bar, the Plus 8 has the mounting points for an engine cover, but no cover as there isn't enough room between engine and bonnet hinge for the big BMW bit, also it isn't long enough as it needs to extend back another 6 or so cm.

This is what it looks like....



I'm tempted to get a couple and see if I can make one to fit!
Every time I wash the car I get water in the tope of the inlet manifold, not a problem, but messy to keep clean.


Peter,
Tarka the 'Otter Mog
2014 Plus 8


Re: GDI Engine Cover progress. [Re: DaveW] #391646
09/09/16 02:34 PM
09/09/16 02:34 PM
Joined: Dec 2008
Posts: 17,949
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 17,949
South Yorkshire
Right then chaps I managed to find enough time. Tested and ready for Cornwall.

Holes enlarged and temporarily edged.
I tried the Dremel to enlarge the holes, but it was no quicker than a hand file and harder to control.
If you need to file the edges of a hole, use a pile of masking tape rolls as a stand and all the filings drop down the middle.



Test fitted and found to be OK. i.e. dipstick pulls out, and oil filler cap pulls out. The oil filler cap on the GDI is a tight fit and a fiddle to remove at the best of times.

I've fitted a collar to the oil cap. This is rubber sheeting. The inner edge is chamfered so that the cap will secure properly.



Next a light dusting of etch primer and satin black.



Then remove the protective film......



....and test fit. At this point I'd planned to edge the whole thing with the same profile as the two access holes, but I've decided it looks OK as it is..................







This is the air gap..........





So we'll see how it performs.

Just an update on the throttle return neoprene block -

This is a 2cm cube of high density neoprene. It actually came as packing in a curtain pole from John Lewis. Double sided tape on one side to fit on top of the throttle lever, which moves towards the bulkhead when pressed. Garage tested but not road tested yet.
What this really needs is a conical coil spring which will compress into one coil width, of the same spring rate as the neoprene block, which compresses but not fully.

If it works I'll see if Cain has access to or can produce such a coil spring, because it might make a cost effective and simple mod to the super sensitive throttle we have at present. I only have one conical coil spring on the shelf and it's the right size but way too soft.





thumbs



DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) Plus 4
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