383 Stroker Valve Cover Mod

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Customer is putting a 383 carb'd stroker motor into a C4 Corvette. Needed this new valve cover modified to clear the wiper motor..  He marked the valve cover a few times where he needed material removed, then I stuck the part in my little bandsaw, and started choppin'.  Had to make the second cut with the cut off wheel.  Next up, gotta make some parts.  Material is 1/8 x 4 flat bar.  I just traced the old part onto the new material, rough cut the corners by hand, then cleaned it up with the flap wheel on the bench grinder.More to follow............ Attached ImagesJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:1.  Nice fit for part one........it just sets there, ready for some heat and filler.2.  I set the flat bar up against the end of the valve cover, and traced it, cut it down with the grinder / cut off wheel, then roughed in the corners.  Copied the angle from the inside of the valve cover, then laid out my lines on the new material.3 & 4.  Rough cut the part with the cut off wheel, then finished it off with a deburring bit in a die grinder.5.  Tacked the parts to the inside of the cover.Next post........... Attached ImagesLast edited by rabidchimp; 03-17-2013 at 04:43 PM.Jet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:1.  Didn't do that good of a job on fitting the 2nd piece, but the gap was manageable2.  I took my time welding this thing up.  Wall thickness on the sides of the valve cover were about 1/16".  Didn't want to put too much heat and have it warp on me.  Probably took too much time, but I'm new to aluminum.  Probably did 1/2 inch at a time on opposite sides of the part, and waited til it was cool enough to handle with thin rubber gloves.  Ran one last bead to fill the low area, then got to grinding and polishing.  I used a ~7" flap disc on my Dewalt to knock the welds down, then cleaned it all up wth 3" scotch brite rolock discs.Customer is super happy, and I got a 10 hp 3 phase motor outta the deal.  Woohoo!  Thanks for looking.-Aaron Attached ImagesLast edited by rabidchimp; 03-17-2013 at 04:54 PM.Jet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:That's going to look good when done.Might want to test fit it on his heads before you weld it up?
Reply:Dallas, I added two more posts with pics.  I was at the guy's shop when he laid out his cut lines.  Take care.-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:Looks good!I have done the same thing when installing a 460 into a '69 Mach 1..Brake booster/master cylinder is in the way..I cut out the corner like you did but in 1 piece then just flipped it over and welded it in.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:It looks good, and I doubt it is very easy to see once installed, but I have a question...Why didn't you take the top of the piece you cut out and make that the lower "shelf?"I was just thinking it was already perfectly shaped, and the would match the top of the valve cover.
Reply:Turned out real nice. Good work.
Reply:very niceDave ReberWadsworth Ohio
Reply:Originally Posted by Fnord5It looks good, and I doubt it is very easy to see once installed, but I have a question...Why didn't you take the top of the piece you cut out and make that the lower "shelf?"I was just thinking it was already perfectly shaped, and the would match the top of the valve cover.