Fabricating this cover was more about patience than anything else. Elected to use the 2no M10 tapped holes in the offside of the cylinder head and the large holes at the top of the nearside intake manifolds to nos 1 and 4 cylinders for plate fixing purposes. The latter have holes about 15mm dia which were subsequently filled with washers to M8 bolts. All bolts, washers and dome nuts from Screwfix or ToolStation for pennies.
A stiff cardboard mock-up was cut to provide approx overall plate dimensions – finalised at 500mm long x 440mm wide. The 2mm thick aluminium plate cost £10 from a local bike show. A 50mm dia timber tree stake was used with the trusty Black ‘n’ Decker work mate to bend the plate a bit at a time to a shape that looked half decent. A slight curve was bent by hand in the middle to permit water to run off each side. Portions at front and rear were cut away from the plate to provide clearance for various hoses etc. and filed to a smooth line. The underside is sprayed with matt black heat resistant paint.
25mm x 4mm aluminium brackets were cut to approx. lengths and bent to suit the final profile of the plate. Both front ones were remade (more trial and error!) to permit the plate to slope towards the front and be parallel to the bonnet hinge – it was originally set level and just didn’t look right. The Dzus fasteners are fine but are critical to the correct amount of washers fitted – even more trial and error needed.
Measurements were taken to establish the centre of the dip stick and oil filler plug relative to the fixing brackets and to each other. 62 mm dia and 72mm dia holes were cut in the plate using an electric jig saw and filed to finish off. The blind rubber grommets (60mm and 70mm) were sourced via ebay ( less than £1each) and stiffened with 4mm rubber sheet cut to size and fixed using Power Bond 806 adhesive.
Abrasive paper in grades P120, P400 and P1000 was used on the plate prior to finishing with Autosol metal polish. I find cut up old bathroom towels are ideal for this purpose.
Looking to embellish both sides with some sort of plate reading “Morgan”. Possibly an aluminium stencil screwed to each side – but not home made this time! Jury is currently out on this.
