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Making a Fiberglass Engine Cover

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Tools used

Referenced tools without an associated photo: Protective gloves

Engine cover part no. 20 is exposed to splashes and may deteriorate over time. The price listed in the original article is historical and needs to be updated. Before reproducing the part, verify that it does not serve any structural or thermal protection function that requires an approved material.

Figure 14.1 — Exploded view of the lower guards, showing the engine cover (item no. 20).
Figure 1 — Exploded view of the lower guards, showing the engine cover (item no. 20).

Overview

Engine cover part no. 20 is exposed to splashes and may deteriorate over time. The price listed in the original article is historical and needs to be updated. Before reproducing the part, verify that it does not serve any structural or thermal protection function that requires an approved material.

Figure 14.2 — Old engine cover covered with a first layer of fiberglass mat.
Figure 2 — Old engine cover covered with a first layer of fiberglass mat.

Explanation

The original article suggests using the old cover as a mold with fiberglass mat or fabric, polyester resin, and its hardener. The quantities listed are approximate: follow the product data sheets, prepare small batches, and ensure adequate ventilation to handle styrene and acetone fumes.

Figure 14.3 — Placement and impregnation of fiberglass strips on the mold.
Figure 3 — Placement and impregnation of fiberglass strips on the mold.

Explanation

Wear gloves compatible with the products, safety goggles, and respiratory protection suitable for organic vapors and fiber dust. Work away from any open flames or sparks. Place the old cover on trestles, apply the fabric, and then gradually saturate it, strictly following the manufacturer’s recommended dosage.

Figure 14.4 — Detail of the layering around the reinforcements and recesses in the cover.
Figure 4 — Detail of the layering around the reinforcements and recesses of the cover.

Explanation

Work in small areas to prevent the material from curing too quickly. After complete curing, deburr and drill while wearing respiratory protection, then check the fasteners, clearances, ventilation, heat resistance, and ensure there is no contact with the exhaust or moving parts.

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