If you’re looking for a way to make your engine compartment stand out, a unique fabricated cover for the radiator core support might be something to consider.
Q.
I’m completely reworking my C10 truck and I want to add some custom features to the engine compartment. I’ve installed a 350 crate engine and I’m considering fabricating a cover for the top of the engine. What other modifications can help make my truck unique?
Pete Boyd
Via the Internet
A.
Well, the sky is the limit for underhood modifications. I have seen many good-looking engine covers over the years, but I have probably seen more that look a bit ungainly, and a few that were downright ugly, in my humble opinion. We’re getting into areas of personal preference here, but I like seeing honest, mechanical features under the hood. If an engine is well detailed and the wiring and plumbing is configured in a tidy manner, I LIKE to see the details of an engine, and covering them up is not always a good move.
I attended the Detroit Autorama recently, and I saw a custom cover made for a core support—unlike any I’ve seen previously. This clever sheetmetal fabrication is the first thing your eye is drawn to when the hood is opened, and it does a great job of filling the opening that you often see between the grille and the radiator.
While I’m not suggesting that you copy this design element exactly, I think it suggests a lot of new directions for styling underhood details. The peaks and valleys in this cover give it a very distinct look, adding a lot of character to the engine bay, and of course you could continue this theme into the wheelwells and firewall, if desired.
I really encourage you to think “out of the box” when designing elements like this. It can give your truck a truly unique look, and make it stand out from the crowd!
Q.
I just finished watching the video of you and Ron Fournier on Hammerforming. One section featured making a form for a part that you needed a copy of. You turned the form upside down and applied Bondo to get the correct shape. How thick did you make the filler at the thinnest point and won’t it crack when you start to hammer the metal over it?
Ed Barras
barrasec@gmail.com
A.
I have made many hammerforms from plastic filler, and a few of them have cracked, but most hold up pretty well. They are often still usable even if small cracks appear, and you can grind the cracks out and re-fill them if necessary.
Of course, the thickness of the filler will have a lot to do with the strength. Usually 1/4 inch or more will give good results, as long as it has a rigid backing. Something like 1/4-inch plywood doesn’t provide a very strong backing, but 3/4-inch-thick MDF or plywood does offer pretty decent support.
The metal you are forming will be a factor, too. Thin aluminum or copper will form much more easily than thick steel or stainless, so your form needs to be designed to be rigid enough to withstand whatever force it takes to move the metal.
There are different strengths of plastic filler, too. Most filler on the market today is “light,” meaning it’s filled with micro-balloons, which make it easier to spread, sand, and featheredge. “Regular” filler is stronger, and then there are plastic fillers with glass fibers mixed in (Kitty-hair and Tiger-hair) and these are MUCH stronger.
There are also “all-metal” plastic fillers that have metal powder added to them, and these are stronger yet.
There are also epoxy “tooling resins” available that are super-strong, but they are pretty expensive, so it’s best to choose the material that’s appropriate for your particular job.
You can email your questions to Professor Hammer – covell@cruzio.com – or mail a letter to Covell Creative Metalworking, 106 Airport Blvd., Suite 105, Freedom CA 95019. You will receive a personal reply! Ron Covell has made many videos on metalworking, and they can now be STREAMED or DOWNLOADED from his website! Check these out at covell.biz
, along with his ongoing series of workshops held across the nation, or call for a current schedule of workshops and a free catalog of DVDs. Phone (831) 768-0705. Also, check out Ron’s YouTube channel – youtube.com
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