Part 5 - Cam Cover modifications and Wing supports
We've altered a standard 2.0L 'Pinto' cam cover to move the high level
oil filler cap to the opposite end. This has allowed us to create a bonnet
template with no bulges or cut-outs.
The lovely colour of the modified cover is, I believe, Ford Mercury Grey.
Its the colour of all those XR3i's and XR2i's that used to fly around.
You can see from the pictures that the existing hole in the cover has been
filled in, also the new hole has a baffle behind it, just to stop any problems
with oil sloshing around near the filler neck.!
Next up is the bodywork. This is a major job, and quite tricky due to the
amount of work required to shape and cut out the material.
The aluminum bodywork has to form the side of the car, the rear section
and the bonnet.
One of the best ways to work out what shape is required is to use card templates....
LOTS of them!
This is probably the hardest panel to get right. There are two common ways to panel the side of the car:
1. A single aluminum panel shaped exactly to fit.
2. Two aluminum pieces. Riveted and sealed approx 1/3 from the front.
We both prefer the single panel aproach to the car and feel it looks much
neater. Unfortunately, the panel has to be perfect the first time, we cannot
remove the frist half of it if we get it wrong (as we could with option
2.)
The most complex part of the panel is the area arount the front suspension
and steering. There are many cut-outs to be made in the panel, and these
must be exact.
Along with the side, and rear aluminum panels, the bonnet also has to fabricated.
Again, we are using card templates to get the exact shape before we actually
use the aluminum.
Another problem with the bonnet arises from the fact that we are using the
2.0 Ford 'Pinto' engine.
This engine is much taller than the regular 'Crossflow' engine, and to make
matters even worse, the oil filler cap, which is the highest part of the
engine, is right at the front!!!!
If nothing were done, then a bulge would have to be made in the bonnet to
accomodate the oil filler cap.
We will try and remedy this situation by altering the tappet cover and moving
the oil filler cap to the opposite end, thereby allowing the bonnet line
to be smooth and level.... Well as smooth and level as we can make it!!!
