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So, I mentioned the new dust cover I want to make and the chunk of stainless I picked up today for it. Well, at first glance I was thinking this would be a simple a cup, similar to the stock dust cover but larger.
After looking closer, I think I'm going to make it a bit more complicated. Still no biggie, but I'm going to have take a few more measurements.
The issue originates with the conversion of a 99 front end to 49mm. The trees and adjuster nut are profiled differently than before and they leave a "huge" gap that exposes the bearing to spray, airstream, etc. More importantly (lol), it also looks sloppy and unfinished. I want to close up that gap, leaving just enough room to get a tool into the adjuster. It'll be smooth and more-or-less solid looking at a glance. It will also more effectively protect the top bearing.
Here's the problem...
This is the basic idea for the fix...
Last edited by cggorman; Sep 20, 2017 at 06:06 PM.
On first fit, the bottom edge interfered by an unknown amount (really hard to measure with no bearing preload and I didn't want to make a shim just to get a measurement.) I guessed and took off a litte too much but I think it's still pretty good. Damn sight better than nothing!
Paint is drying now.
The leading edges are a little off. For some reason, the outside diameter of the neck and the bearing bores are not concentric. If I try to get them in line, there's only like .010 of thickness on my spacer where it overlaps. I set it at like .035 to make sure it was somewhat durable. Good enough.
Last edited by cggorman; Sep 23, 2017 at 02:10 PM.
Stepping up my polishing game, too. Got some new compounds and buffs specifically for stainless and aluminum mirror finishing.
stainless axle cap that was scratched up (Klock Werks mentioned up top there somewhere) and some 7/16-14 ARP bolts I had to shorten.
I've seen some of your mad polishing skills with a mirror finish! Looks great man. I've got a triple tree to work on. Feel like knocking it out for me? I kid..
Your science project is top notch and far exceeds my mechanical skills. Thanks for sharing. Looking forward to seeing it all come together.
On first fit, the bottom edge interfered by an unknown amount (really hard to measure with no bearing preload and I didn't want to make a shim just to get a measurement.) I guessed and took off a litte too much but I think it's still pretty good. Damn sight better than nothing!
Paint is drying now.
The leading edges are a little off. For some reason, the outside diameter of the neck and the bearing bores are not concentric. If I try to get them in line, there's only like .010 of thickness on my spacer where it overlaps. I set it at like .035 to make sure it was somewhat durable. Good enough.
Metal finished and radiused the inlet on the tube. Then painted it with VHT Wrinkle Plus. 3 heavy coats, 5 minutes apart, wait 45 minutes to tack up, then warm the part to about 120 degrees. I use a heat gun, gingerly. Too much heat or uneven heat (or paint) can cause uneven wrinkling. Works every time.
Polished the Norma hose clamps...because...why not? Very nice result. Good clamps. 100% stainless, including the screw. Highly recommended when Oetikers aren't appropriate.
Got the black filter oil and treated the filter. No visible difference on the pre-blackened gauze, but I also tested it on a white cotton rag just to see.
I've used Green Filter products almost as long as K&N. Always pleased. Had one of their cone filters on a daily driver for about 13 years and 200,000 miles. Car rusted away and the filter never gave up. This is my first time using their oil but I have no concerns.
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I kid..
