BigValve style valve cover for TOYOTA 4AGE 16V engine

[ralf]

With my small cheap milling mashine I cut the area where there is a waterplug at the 4AGE cylinderhead.

[ralf]

The hole for the oil filler was cut, first with a circlesaw.

[ralf]

The exact diameter was made with a boring head. Final the axial surface was cut.

[ralf]

The pins which hold the filler cap were made of aluminium. They are screwed in and fixes with LOCTITE.

[ralf]

The cover is made for the filler cap of the Lotus TC

[ralf]

A fiend of mine who has a big milling mashine cut the planar surface of the cover and drilled the 8 bores.
My cover did not use a gasket. I will use silikone.
Next I make a light countersunk to the 8 bores and mesured the gap betwen the head anf the cover.

[ralf]

To reduse the stress in the cover when tighten the 8 nuts holding the cover, I want a clearance between the countersunk of the bores and the struds of 0,05 to 0,1mm.

[ralf]

The cylinderhead and valvecover need an opening for the O-ring area of this bracket. because I dont have a big milling mashine I used a manual Hunger valveseatcutter. A guide was made to position the cutter in the center of the camshaft.

[ralf]

With he Hunger I cut the bore in the head and the cover fixed together.

[ralf]

Maybe the most complicated work was to mashine the radius which will seal the cover to the first bracket for the camshaft. Because I don't want to damage the front of the cover I could not use a milling mashine (I dont have somebody with a CNC Mashine). It was done by positioning a guide to the cover und use a homemade cuttingtool which is driven by a drilling mashine. Finaly I could do it with a clearance between cover and head of 0,05 to 0,1mm, which can easy sealed by silikon.

[ralf]

Before painting the cover with VHT Wrinkl Plus the cover was cleaned with aceton and some surfaces get masked.

[ralf]

After spraying the cover it was heated up in a oven at around 90°C.

[ralf]

Finaly some areas were sanded down to the aluminium to get the TC like design.

[BDA]

Great stuff, ralf!!! Very neatly done! I'm anxious to hear about the rest of the car!

[GavinT]

Phew . . what an absolute over the top spectacular undertaking, Ralf.
Very well done.