ALum Covers

**BDowning** · 03-10-2009, 06:53 AM

I'm starting a large project, making new alum parts for the engine bay. I will be manufacturing new pulleys (4), air box and lid, battery box, power brake cover and power steering cover. brackets for the hood, cover for the computer. I have all ready polished all 4 calapers the power steering cooler Polishing everything to a high gloss and then clearing all of it

Bill

**JoshieDoom** · 03-10-2009, 06:58 AM

Subscribed to see the lower airbox installed. I know these would cost an arm and a leg to make but dam they look good.

**BDowning** · 03-11-2009, 04:03 AM

I need to start on the lid this weekend, this should be a real challange!!

Bill

**sstg** · 03-12-2009, 09:45 AM

Show us some polished pics.

**BDowning** · 03-12-2009, 09:56 AM

this weekend I'm making the lid and a cover for the surge controler for the brakes, where all the wires are coming out the back.

As soon as I get everything built i will start on the polishing

Bill

**sstg** · 03-12-2009, 10:05 AM

Originally Posted by BDowning

I have all ready polished all 4 calapers the power steering cooler Polishing everything to a high gloss and then clearing all of it

Bill

I thought you already did some polishing...is why I asked.
Cool post them when your done please.

**BDowning** · 03-12-2009, 10:23 AM

Originally Posted by sstg

I thought you already did some polishing...is why I asked.
Cool post them when your done please.

Your right!!!I polished some stuff last year and will re-do some of this year. The valve cover, and calapers. The power steering cooler I did also , but this year I'm going to weld 90deg alum tube on the ends of the cooler and just have short piece of hose on each end

Bill

**yyun** · 03-13-2009, 02:48 PM

Great job on all the projects. That stuff looks heavy though. Do you have any suggestions on how to weld aluminum as good as you do?

**BDowning** · 03-14-2009, 04:28 AM

Originally Posted by yyun

Great job on all the projects. That stuff looks heavy though. Do you have any suggestions on how to weld aluminum as good as you do?

Truly, the weight is not that much. The alum air box base weighs no more then the factory base.

to weld Alum you really need to have a big enough welder to do the job. I'm no pro by no means. It's been 10 years since the last time I welded any alum. Practice practice practice.......some times pre heating alum helps, it makes the puddle flow better.

To day I'm going to start on the lid.........now we will see how good I am. This is going to be a big challange. I'll post a pic at the end of the day

Bill

**BDowning** · 03-15-2009, 07:38 AM

After a long afternoon I did get most of the lid finished, not easy by any means. I had to learn to be part Blacksmith. Getting straight metal to go around a round object is just dam tuff

This is how this all started, with template fo all the parts

**BDowning** · 03-15-2009, 07:51 AM

Laying the metal out and cutting it

My wife helps with the saw cutting

A little tig welding and

Lid & Bottom

Bottom put together

Lid

The under side of the lid...not finished

On the car....and I can close the hood!!!!!

Pics of the waterpump , removeing the pulley so that I can polish it

**TempleU_WS6** · 03-15-2009, 03:00 PM

Some great work you have going on there. Any more progress pics?? What is the best way to polish the metal? I plan on polishing and painting my calipers and polishing a lot of parts under the hood.

**sstg** · 03-15-2009, 04:06 PM

Very cool man, great job.

**third_shift|studios** · 03-16-2009, 06:43 AM

epic

**08 Vette** · 03-16-2009, 08:13 AM

Looking good! Damn that's an old baned saw, the last time I saw one that old was when I worked at Oakley Die & Mold. We had to start the Surface grinder with a lead babbit! LOL

**BDowning** · 03-16-2009, 08:26 AM

Originally Posted by 08 Vette

Looking good! Damn that's an old baned saw, the last time I saw one that old was when I worked at Oakley Die & Mold. We had to start the Surface grinder with a lead babbit! LOL

Tim you are old....lead babbitt....i know what that is

**0verkill** · 03-16-2009, 12:32 PM

thats looking good. what shop is that in the pics?

**BDowning** · 03-16-2009, 04:04 PM

Originally Posted by 01 T/A

thats looking good. what shop is that in the pics?

UPI Inc. Blue Ash

We will machine anything........trying to get a plug!

**4get gto** · 03-16-2009, 04:13 PM

Originally Posted by 08 Vette

Looking good! Damn that's an old baned saw, the last time I saw one that old was when I worked at Oakley Die & Mold. We had to start the Surface grinder with a lead babbit! LOL

Guess its showing you that old can still do good........

Kinda like what I see.. Interested.....