Valve Cover Baffle Project

greengoblin · 10-26-2010, 08:48 AM

We had been left with the choice two choice when we want to add fittings or media blast our VC for powder coating.

1. Take the baffles out and leave them out.
2. Leave them in. Cross our fingers and pray nothing became hung up under them and then later dislodged wreaking havoc.

I don't think either of these are good choice so this is what I came up with. I had several very good friends help me with this.I the love the way it turned out. Take a look and see what you think. Nothing super radical just an Aluminum version of the OEM units. The first unit is going to be on Andrew's timeattack eclipse!

Big thanks to Brendon For setting up the drawings for the plasma cutter.

First baffle fully welded together. Now the AN fittings and baffle need to be welded to the VC then on to coating. Thanks to Travis for welding the tabs on the baffles for me!

Andrew's VC for his time attack eclipse.

-10an fitting with custom baffles.

Calan · 10-26-2010, 08:56 AM

That's awesome.

Where did you weld the baffle back into the VC Kevin? I don't see any welds in the bottom pic.

99gst_racer · 10-26-2010, 09:05 AM

That turned out very nice.
I had considered recreating the baffle out of aluminum too, but it would have taken me forever doing it all with hand tools. I never got beyond making a cardboard pattern for it.

You're doing your VC the same way, right? I'm surprised Andrew didn't want a screw-on filler for his.

VETTE_50_TH · 10-26-2010, 09:27 AM

Two words. How much?

greengoblin · 10-26-2010, 09:30 AM

Quote:

Originally Posted by 99gst_racer

That turned out very nice.
I had considered recreating the baffle out of aluminum too, but it would have taken me forever doing it all with hand tools. I never got beyond making a cardboard pattern for it.

You're doing your VC the same way, right? I'm surprised Andrew didn't want a screw-on filler for his.

Drew was in a hurry and I didn't even think to ask him. I don't think he will mind though.

I glad I didn't have to use hand tools. I came close too. your right it would take some time but it's very doable.

Quote:

Originally Posted by calan

That's awesome.

Where did you weld the baffle back into the VC Kevin? I don't see any welds in the bottom pic.

Just along the sides in a few places. I didn't get pics but will take some when I do mine.

Quote:

Originally Posted by VETTE_50_TH

Two words. How much?

I'm not a vendor so I can't talk about that. To use the plasma table I had to do five sets. Four are already gone. I don't know it I'll make more or not. You can Pm if you like.

fwdmaster · 10-26-2010, 10:14 AM

Great job on the baffle mod greengoblin, attention to detail

Calan · 10-26-2010, 11:21 AM

Quote:

Originally Posted by 99gst_racer

I had considered recreating the baffle out of aluminum too, but it would have taken me forever doing it all with hand tools.

Yeah... if only you knew someone with access to a plasma cutter.

greengoblin · 10-26-2010, 12:34 PM

Quote:

Originally Posted by fwdmaster

Great job on the baffle mod greengoblin, attention to detail

Thanks!

Quote:

Originally Posted by calan

Yeah... if only you knew someone with access to a plasma cutter.

It is quite nice. I still had to pay to have five cut out. So it was not free. Also I would have liked for the the resolution of the table to have been better than it was. Still I'm happy.

Calan · 10-27-2010, 05:39 PM

Quote:

Originally Posted by greengoblin

It is quite nice. I still had to pay to have five cut out. So it was not free. Also I would have liked for the the resolution of the table to have been better than it was. Still I'm happy.

I was just giving Paul a hard time because I have access to a plasma and probably could have cut one out back then when we weren't so busy.

Imback · 10-29-2010, 11:32 AM

Nice work i was thinking of doing the same but with a manual plasma.

greengoblin · 10-29-2010, 01:04 PM

I'm revising them a bit. My friend Travis came up with some very good ideas. I'll post up pics when I make the new one.

Kevin

EclipticalGS · 10-31-2010, 02:21 AM

I have considered making one manually and then just stitching it in a few spots to hold it down and tight but like Paul said, I drew it up on Cad and marked it on a alum. sheet but never got around to actually cutting it out. Now I may be forced to use Ford specialty rivets, but PM sent!

Another thing I thought was tapping a couple holes and putting some bolts in, and then tacking the bolt heads to the stock baffle plate. eeehh

or. Cutting out strips of alum. like 1" by whatever width that will string from one side to another, like a support, and then tack a couple of those in some spots. But then the cams will probably hit those, Im not sure of the clearances under there.

Id bet theres a decent market for these, I know of 6-7 people that are/were in the same boat as me, Hell you could make these new ones function better than stock and im sure people would buy them..

Good job!

greengoblin · 10-31-2010, 07:19 AM

I'm revising them as we speak and will be cutting out some more. I'll post here when I do. IT going to be a few weeks.

Kevin

NeMiZiS · 02-08-2011, 11:53 AM

I just ordered a new valve cover with the baffles removed.
I'm trying to figure out a way to re install the baffles.
How are you attaching the new baffle, to the valve cover?

99gst_racer · 02-08-2011, 01:17 PM

I'm sure Kevin welded his alumnum baffle in place. But the factory baffle is steel, so you wouldn't have that same option with it. I've read where others have used a welder to build up the little "buttons" that protrude through the holes on the baffle. Then with the baffle installed, they mushroomed the aluminum buttons to retain the baffle.

This is the only solution that I can think of other than using a screw-type fastener (which I'm not sure I'd fully trust).

NeMiZiS · 02-08-2011, 02:00 PM

Yea I figured they had to be welded back in.
I just don't have a welder or the know how to do it.
Here is the Valve cover I bought.
I guess I might just have to re sell it.

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greengoblin · 02-08-2011, 04:18 PM

You "could" use very small rivets to hold it in place. Drill holes, put JB weld in holes, install rivets, then put JB weld on the tops of the rivets. I did this YEARS ago and the VC that has them is still in use with no problems. Is it ideal? No! Is it smart? uuummmm

Did it work on the VC I did. Yep.

Do what you will.

Kevin

EagleTSIawd · 02-08-2011, 04:30 PM

The OEM valve cover has a gasket that goes all around the baffle, did you use a gasket? or just weld it in place?

BigBeans · 02-08-2011, 04:37 PM

I brought mine to a machine shop, and they used a machine to drill and tap where each spot weld was.

After that they put tiny screws in, and i tacked each one to the baffle.

OEM baffle reinstalled, and bulletproof.

EclipticalGS · 02-08-2011, 04:52 PM

I was stuck in the same situation. I just ended up using gravity to run aluminum beads down the inside of the valvecover to where the steel baffle was. With enough heat in some spots I was able to actually get my alum. drip above, and below the steel baffle. So its pinching it in about 16 spots.

Also, I put some blob welds on the existing aluminum rivets to hold the baffle down. No gasket was installed and I havent had any problems. My catch-can catches the same amount of oil it used to, and all my welds looked the same as they did 2000 miles ago.

greengoblin · 02-09-2011, 01:01 PM

Quote:

Originally Posted by EagleTSIawd

The OEM valve cover has a gasket that goes all around the baffle, did you use a gasket? or just weld it in place?

No gasket and no problem.

Kevin

snowborder714 · 02-09-2011, 01:22 PM

Quote:

Originally Posted by NeMiZiS

Yea I figured they had to be welded back in.
I just don't have a welder or the know how to do it.
Here is the Valve cover I bought.
I guess I might just have to re sell it.

HOLY OVERSPRAY! May I ask where you bought it from? If you don't feel comfortable posting it, just send me a PM.

Kevin, any updates on the redesigned baffle?

NeMiZiS · 02-09-2011, 02:33 PM

It is an e-bay special.
I was just itching to spend some money, didn't look real close at the auction.
I have been wanting the Hyundai valve cover and I just got excited.

It hasn't came in yet, I just re-posted the pictures from the auction.
Here is a link to the auction..
ECLIPSE TALON HYUNDAI 2.0/2.4L 4G63 DSM RED VALVE COVER - eBay (item 290526293922 end time Jan-31-11 00:31:46 PST)

greengoblin · 02-10-2011, 10:19 AM

Quote:

Originally Posted by snowborder714

HOLY OVERSPRAY! May I ask where you bought it from? If you don't feel comfortable posting it, just send me a PM.

Kevin, any updates on the redesigned baffle?

I'm hoping my guy gets in gear. If not I'll have to take the stuff out of his hands.......

2slow4utsi · 03-17-2011, 10:19 AM

Any updates?

snowborder714 · 03-17-2011, 10:29 AM

I got an update from Kevin the other day.

Quote:

I'm still working on them. Well i'm waiting for my friend to get off his ass and show mw results. We talked a few days ago and I solved a few problems he was having with the design. I hope to here back from him soon.

2slow4utsi · 03-19-2011, 02:46 PM

Perfect.

dsmTripp · 04-26-2011, 07:29 PM

Any updates to the changes in design or anymore information Kevin? Just read a similar post on another site that sent me here.

greengoblin · 04-28-2011, 07:18 AM

Here is the final design for my aluminum VC plate and baffles. They are made with a tooth in slot design for maximum strength and to make locating the baffles easy . If you have any question let me know.

Brain I need to get info abot being a freelance member on here. I do not want to step not want to step on toes. This was ment to be a look what I made thread. Now I feel it's turning it hey I made these who want them. This is not intent of this area.

Kevin

VETTE_50_TH · 04-28-2011, 08:46 AM

Do those tabs need to get welded or what?