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Airlid repair

This is a discussion on Airlid repair within the External Engine forums, part of the LSx Technical Help Section category; So I got this WS6 airlid tray that was broken up pretty bad. Picked up a non WS6 air lid ...

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    Spaz is My Mentor SMWS6TA's Avatar
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    Airlid repair

    So I got this WS6 airlid tray that was broken up pretty bad.





    Picked up a non WS6 air lid donor from a local junk yard.


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    Spaz is My Mentor SMWS6TA's Avatar
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    After I trim off the broke edges I then cut a piece off the donor and then like welding metal, start tack welding the two together.



    Here you will see that I added some strips of speaker wire across the two pieces. This will add more strength. You use the soldering iron to heat up the wire and then press into the plastic. Be careful not to hold too long otherwise you'll burn thru.


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    Spaz is My Mentor SMWS6TA's Avatar
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    On the underside you don't have to make it look pretty. I used some cut pieces from the donor to build up material. I also used a heat gun to soften the plastic making it easier to mold. I also used it to remove the the yellow goop from someone's previous attempt to fix this.







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    Spaz is My Mentor SMWS6TA's Avatar
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    On the top side I feather it out trying to make it look a little better. Here you don't add material if possible.




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    Spaz is My Mentor SMWS6TA's Avatar
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    Next I took a sander and smooth out the top side to knock off the excess plastic and any high spots in prep for body filler.






    I now apply body filler to the top side to fill in these ugly lines...




    I let it set over night.

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    Spaz is My Mentor SMWS6TA's Avatar
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    Break out the sander again and start sanding down the filler. Use different grades to smooth it out.










    So far so good. The lid is much stronger than before. Prior to the filler, I applied significant pressure along the weld to see if it would break and it didn't give a bit.

    Next I'll trim for the free air mod and sand a little more. Once it's cleaned up I'll prime and paint. Post those pics when finished.

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    awesome job man! looks great.

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    That is looking good. Can't wait to see how the finished product turns out.

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    My little issue issue is what to do with the sticker on the right side. It's a factory sticker and not sure if able to remove it with the heat gun will let me reuse it latter. Honestly don't care but it does give it a factory look.

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    if you have a color printer you could always design and print your own sticker........or design it and take it somewhere to be printed.

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    Nice work, Scott.

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    You did a very good job repairing the air box, but the question I have is how you break the air box in the first place?

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    Scott's a tool chucker when things go wrong. At this point, he has thrown every tool he owns!


    Actually, I think he picked it up used in that condition.
    SMWS6TA likes this.

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    Veteran 0rion's Avatar
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    hmmmm.....I was gonna guess he dropped a main bearing on it.

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    Senior Member theorangeguy's Avatar
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    Quote Originally Posted by 0rion View Post
    hmmmm.....I was gonna guess he dropped a main bearing on it.
    Hahaha I laughed at that one...


    Scott probably won't tho.
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    Quote Originally Posted by 024mula View Post
    You did a very good job repairing the air box, but the question I have is how you break the air box in the first place?

    Was given to me that way. I think it was from an accident.
    Quote Originally Posted by pajeff02 View Post
    Scott's a tool chucker when things go wrong. At this point, he has thrown every tool he owns!


    Actually, I think he picked it up used in that condition.
    1st part is true....as well as the 2nd

    Quote Originally Posted by 0rion View Post
    hmmmm.....I was gonna guess he dropped a main bearing on it.


    Quote Originally Posted by theorangeguy View Post
    Hahaha I laughed at that one...


    Scott probably won't tho.
    That did make me laugh....

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    well I put on a preliminary coat to see how it's going to look. Still see some dimples that I need to fill in some more but it's coming along.

    Wondering if I should just Hydrocoat it and have it hide the seam.



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    Veteran 0rion's Avatar
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    looking better but I think you can get those dimples out with enough work. You came this far....don't short cut it now. If you do paint it make sure you use a self etching primer so the paint is less likely to flake off.

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