Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing GDI Engine Cover progress.

Hi Simon. If heading south then yes it was us.

Yup, I was going in the other direction.

The colour of the new car definitely stands out in the rain!!

Simon @ SiFab.co.uk

Did you wave?

With the weather as it was it would have only been a bow wave....

Would you have noticed a Ford S-Max Daddy wagon driver waving at you anyway?

Simon @ SiFab.co.uk

Probably not, given the weather........

Post Photobucket re-post.....................

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.

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.
UPDATE: I eventually removed the rubber collar.It was OK without it.



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.

UPDATE: Very good performance in monsoon conditions. This modification is well worth doing.