Custom CNC-milled spark plug wire cover.

[CBR]

The stock spark plug wire cover on my '96 GSX was falling apart, so I started looking for something aftermarket. The only aftermarket one I found was made by Extreme Motorsports, which I didn't like too much. Their design was a solid cover with no vents. This I figured was not too good, since the sparkplug wires will be operating in high temp. conditions. I don't know about you, but have you ever felt your spark-plug wires after the engine has been running? Get's darn hot. I don't know if this affects the performance of the wires, but over time, heat seems to wear everything out.

So why not just leave the cover off? I didn't like the look of it. Everytime I looked under the hood, I couldn't stand the thought of something "missing."

So I decided to make my own spark plug wire cover. A buddy of mine owns a CNC lathe, so after quite some time,about a year, we finally came up with something.

Below is the first one we've made. Please leave me some ideas, likes/dislikes, etc. I have more pics if you want to see them. Let me know.

THANKS!

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[Chuckt]

How much. I seriously want one of these. I would honestly buy one. If you can sell them at a decent price or something I will be the first to buy one, Nice work

 

[wastefuldreamer]

Looks good

 

[RipperXX]

I would only change one thing.. make a hump around the vents you know rais it up just a little.. nice and smooth.. do that and i would kill for one..

 

[TURFNNSURF]

I say try to do one with the Diamond Star symbol for cut outs, that would look really Tight.. Just my 2 cents...

 

[Defiant]

Nice-looking. How the devil did it take you a year?

 

[CBR]

Thanks for the comments so far.

Chuckt...I'm still working on a few design changes here, I'll let you know when the final one is milled. Just keep checking back to this post.

RipperXX...I think I know what you mean. The pics I posted just doesn't do it justice, if you're a member of imagestation.com, do a search for 4g63. Go into my photoalbum, and there are a lot more pics, plus they are larger, so you get a much better pic. I had to scale them down here to make them web-friendly.

Defiant...it took awhile, since this was an off and on project. Plus it doesn't help too much right now, since my GSX suffered from crank walk; destroyed the crank shaft, block, rods, crank sensor, and who know, some other things. I'm still tearing it apart. sucks.

turnnnsurf...the diamond star, I was working on this at one time, but wasn't too successful. When I get a chance, I'll try again.

Thanks for looking. Keep the comments coming. Here are a few more pics.

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This one here is an under view.

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This one here is a close up of the spark plug wire guide. Pain in the ass to program and mill correctly. I had to mill the opening to fit my Magnecors, plus, it also fits the stock wires, but just a tad bit loose.

Man, I wish my GSX was still together, then I could take a pic of it installed....anyone in the St. Paul, MN area?

 

[RipperXX]

hmm... still think a little hump around the vents would look better but it's better than i thought in the first pic.. also so what if the stock wires are lose just put a few rounds of tape around them and stick them back in...

 

[CBR]

RipperXX....yeah, that's a good idea, put tape around the stock wires to make them a little bit thicker in diameter, that way they'll fit snug. About the "hump," if I get some time this weekend, I'll mess around with the design again.

 

[98TsiAWD]

That looks like ALOT of work, gonna be spendy?

 

[RedTurboEclipse]

that looks nice man..

i always wanted the spark plug cover from RRE.. excuse the very big pic..

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but for 70-90 bucks.. its something that can wait.. if you start selling those bad boys u are making with a similar/better design for a lot cheaper.. add me to the list.. keep up the good work on those custom milled sp wire covers..

 

[CBR]

98TsiAWD.....yeah, you're right, it is a lot of work. It took a lot of time programming, then it was all trial and error on the milling machine. And by the way, milling machines are NOT cheap. Not only that, bulk aluminum gets expensive.

My spark plug cover was designed and made in my friend's garage. I should show you guys some pics of where the spark plug cover all starts. It's all done in house; custom.

RedTurboEclipse.....That RRE one doesn't look to bad. That's the first time I've seen one of their covers. It's interesting to see that they offer it in a raw finish, and polished. I guess I never really thought about leaving my spark plug cover plain. It just doesn't appeal to the eye.

 

[98TsiAWD]

Originally posted by CBR
98TsiAWD.....yeah, you're right, it is a lot of work. It took a lot of time programming, then it was all trial and error on the milling machine. And by the way, milling machines are NOT cheap. Not only that, bulk aluminum gets expensive.

My spark plug cover was designed and made in my friend's garage. I should show you guys some pics of where the spark plug cover all starts. It's all done in house; custom.

RedTurboEclipse.....That RRE one doesn't look to bad. That's the first time I've seen one of their covers. It's interesting to see that they offer it in a raw finish, and polished. I guess I never really thought about leaving my spark plug cover plain. It just doesn't appeal to the eye.

Yeah, I also make spark plug covers, not as fancy as yours tho: http://www.pbase.com/98talontsiawd/spark_plug_well_covers

 

[Chadillac2000]

I Definitely Want One!!! How Much, The Slits Look Way Better Than The RR One, Can't Wait Til U Get These Ready, And I Want One With Magnecor Slots, PM Me If Ya Get Them Ready!

 

[CBR]

Originally posted by Chadillac2000
I Definitely Want One!!! How Much, The Slits Look Way Better Than The RR One, Can't Wait Til U Get These Ready, And I Want One With Magnecor Slots, PM Me If Ya Get Them Ready!

Chadillac2000....you got PM.

98TsiAWD....it's a good start. I'm still messing around with the CNC mill, there are so many things you can do. The problem is that I just don't have the time to figure it out. Hey, I'm working on lettering soon. Maybe I can make one with your sig on it....98TsiAWD.....I'll keep you posted.

 

[RipperXX]

hmmm what about one that has TSI cut out in it? like in a cool gothic text (that would probly be a bi*** with programing the mill)

that or something like

"Gone V8 hunting"

 

[greathuskie]

if you could cut out TSi in the middle and leave only that...i would defenitely buy one

 

[rubbersidedown]

very interesting. i'd definitely like to see some more designs

 

[CBR]

To you guys that want the "TSi" on the cover. Find me a font that you would like the letters to be, and I'll see if I can mill it.

 

[RipperXX]

(cool he's useing my idea)

will you do it in any size we wish? far as the text i mean.. becouse i want it pretty big when i get around to ordering one.. i mean it does need to vent but look cool too...

 

[CBR]

I'll let you pick the font, get about 5-10 other guys that want the same thing, and I'll consider making it. Font size will depend on what I can get to work. For now, find me the font that you want.

 

[gs-tclipse]

how bout a gst cut or gsx

 

[eclipse93b]

I live in minneapolis. if you want it shown on a car ill be glad to let you use it on mine. Just pm me and i can cruise on down there whenever.