Acrylic Spark Plug Cover

[CONSIGLIERI]

I WOULD DEFINITIVELY BUY ONE ALSO !

Congrats !!!!

 

[DROOPY209]

If you use a router with a template cutting bit, you could cut these out effortlessly from Lexan. You would just have to drill out the bolt holes.

 

[Gamble97]

Anyone make a spark plug cover in a dxf file? I have a few contacts that can CNC them.

 

[keithcfisher29]

Great work I'd love to have one too.

 

[Jon91TSi]

It will probably start to develop stress cracks if the bolts are tighter than finger tight. I found that running washers on both sides of the plexiglass with larger than normal bolt wholes reduced cracking. I've been running mine for a little over a year now. You may also have some problems with the one edge chaffing the spark plug wires where they exit the cover. Also, don't get any coolant on it, ever. It will eat into the plastic.

A dremel with a sanding wheels helps with the curves. Use it on the low speed. I finished smoothing the curves by hand with sand paper.

But good job. I get complements on mine all the time.

A propane torch also works great to smooth the edges of the plexi/lexan/acryllic. If you're not careful with a dremel or by hand, you'll end up with all kinds of sanding marks that can't easily be removed. A torch will make a nice smooth rounded edge.

 

[Ravenous]

Dang it... I was going to mention the router and flame polishing the edges but got beat to it.... So otherwise, Great Job! I may whip one of these out, use our Silhouette to cut out some vinyl for a mask, and then bead blast it. Last thing I need is another project, thanks a lot man

 

[CONSIGLIERI]

Will this be sold.???

 

[northernawd]

I'd be down to buy one or two covers.

 

[EisHERE]

I only got scrap plastic for $3 per .lb. And the only stuff they had was this acrylic, some stuff that is replacing glass but is harder to repair if scratched, also harder to scratch too. And they had black Acrylic which wasn't transparent. They have tons of colored transparent stuff but not scrap, just full sheets. Which if I end up with a perfect way to cut and a trace, I'll buy a couple different colors, cut them, wrap them and throw them on ebay for maybe like 30 shipped with bolts.

THIS!!! I would buy one for sure!!!!!! great idea you got going. you could really help pay for your build with this. definitely a good idea man. I'm sure a lot of people would want one.

 

[RipperXX]

Whats the temp rating on something like that? Our engine bays get pretty freaking hot in the summer, especially after a little goofing off.

 

[knochgoon24]

I had a cooling issue and the logger showed 258*F before I got it to a safe place to pull over. Still no damage to mine.

 

[silvreclips]

Acrylic is rated around 170F. Lexan would also be a good material to use. I can have a few of these cut out on a waterjet if some people do want them.

 

[InfiniteGSX]

First off there are different types of plastics, some for low and some for high heat. Some are tougher and some are softer. I've given a couple of my scrap learning pieces to some people and they are still using them today. I haven't used mine since I'm being lazy to finish my wire tuck.

Another thing you gotta think of how heat is distributed. How these must be installed allows them to hardly touch any surface besides the bolts.

I say if someone wants to make one, be sure to get the specs of the plastics your wanting to use. The place I got mine from had stuff capable of withstanding some pretty high heats.

Also as for production, Come spring time I plan on making 20 or so identical copies to sell to JGT Customs (best prices I've come across for any powder coating job) and they will be selling them as a kit with bolts and washers. I think he's gonna sell the kits for like 40 bucks shipped. I might make more but right now my mind is focused on my house, praying my yard makes it through the winter and finishing my car. But it will be posted on here so just keep your eyes on this forum. DSMTuners.com is the only site I visit.

 

[knochgoon24]

For those curious, I found a scrap of the stuff I used with the backing still on it. It is Makrolon by Sheffield Plastics. I think it is the GP version. Good to 280°F.

 

[Paintballaa5]

First off there are different types of plastics, some for low and some for high heat. Some are tougher and some are softer. I've given a couple of my scrap learning pieces to some people and they are still using them today. I haven't used mine since I'm being lazy to finish my wire tuck.

Another thing you gotta think of how heat is distributed. How these must be installed allows them to hardly touch any surface besides the bolts.

I say if someone wants to make one, be sure to get the specs of the plastics your wanting to use. The place I got mine from had stuff capable of withstanding some pretty high heats.

Also as for production, Come spring time I plan on making 20 or so identical copies to sell to JGT Customs (best prices I've come across for any powder coating job) and they will be selling them as a kit with bolts and washers. I think he's gonna sell the kits for like 40 bucks shipped. I might make more but right now my mind is focused on my house, praying my yard makes it through the winter and finishing my car. But it will be posted on here so just keep your eyes on this forum. DSMTuners.com is the only site I visit.

Twenty? I'll be checking that site everyday!

 

[Marc91GSX]

Another thing to consider with this stuff is the type of cleaners you use on the plastic. I have a friend who works for a company that sells Alumax Showers and other glass products. That company also gets sheets of lexan and we built a speaker box out of 1/2". It came out really good but he used a glass polish on it for a car show, it really looked good so he kept on using the stuff. About a year later we noticed cracks forming inside the lexan. They were not all the way through but very visible so he called lexan about it. Apparently the acrylic glass is infused with a type of oil and certain cleaners will suck that oil out of it causing the glass to dry out and literally rot from the inside.

Only use ammonia free cleaners or polishes on it, other than that the stuff is (quite literally if thick enough) bullet proof.

 

[2gSpyder4g64]

wow this is the same thing ive been working on today, i have a sheet of acrily laying arround and i dont have a spark plug cover,
so i said why not haha, just im gonna use laser to cut cause i dont like cutting myself : /

i'll let you guys know how it turns out.

heres a few pics of how i made it:

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took measures and used a dummy to see it it fits

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and it did

and heres the cad drawing

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i have an apointment with the lasser cutting guy at 6 pm today, i'll update to show the end result

 

[Marc91GSX]

wow this is the same thing ive been working on today, i have a sheet of acrily laying arround and i dont have a spark plug cover,
so i said why not haha, just im gonna use laser to cut cause i dont like cutting myself : /

i'll let you guys know how it turns out.

heres a few pics of how i made it:

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took measures and used a dummy to see it it fits

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and it did

and heres the cad drawing

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i have an apointment with the lasser cutting guy at 6 pm today, i'll update to show the end result

Wow, I want a CAD program so bad .

 

[2gSpyder4g64]

Wow, I want a CAD program so bad .

haha you can get them free and legal from facebook haha
look for autodesk students and use the app and you get all autodesk programs for free aslong your a "student" haha
well heres how it came out
theres not much light and its cell phone pics so sorry for bad quallity, (+ the flash doesnt help) haha
in person it looks awesome haha

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i'll post day light pics

the best of all i had the acrilyc laying arround collecting dust and i spent 5 dls on the laser cut haha, so each cover price was 1.25 dls not bad ;o

 

[InfiniteGSX]

Who did the cutting? I'm interested. But looks like you should upsize it like 1%. Looks like a few things aren't lining up right. The holes and the angle. Also try going with a thicker plexiglass, the thin stuff looks real cheap.

LMK on the cutting.

 

[2gSpyder4g64]

Who did the cutting? I'm interested. But looks like you should upsize it like 1%. Looks like a few things aren't lining up right. The holes and the angle. Also try going with a thicker plexiglass, the thin stuff looks real cheap.

LMK on the cutting.

the cutting was made by a local architectual studio, they let use design students use i the machine, it can cut up to 9mm acylic/plexiglass.
your right about the holes they dont line up, i used a pen and estimated the distance haha but it ended up being wrong by 2mm ( it looks worse on the pics beacuse of my plugs are messy) haha.

Like i told you on the pm i already fixed that problem , and i also extended the left side of the cover 2mm so it fits tighter.

the problem im having trouble with is near the oil cap, i left a pretty big fillet as i want sure it would fit, i think i have the right proportions on paper now i need to re update the file i sent you. and test it.

and for the cover being to thin i agree it looks cheap ( and it was), but since i had the material lying there i deiced i would put it in good use.

I used a 2mm sheet, in the past days its been holding on with no problem ( decoloration, melting, deforming).

i put 2 of them and they look alot better that way.
so my guess is to use a 4mm-6mm sheet next time.
im sure it will hold with no problems.

i put a washer under and over to prevent craking by over thighting.

other of my problems is that the engraved is to thin, but making it wider or filling it increse the cost of the laser. and it was a test, so its fine for me right now.

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aslo the pic does not justice to it , in person it looks pretty sweet.

 

[talonalex92]

These would be cooler, if they weren't clear...just saying.

 

[Total Eclipse]

Looks good. I am getting one I did waterjet cut out of 304 Stainless steel that I am gonna polish. My letters will be cut out, and I will have a strip of Blue surface mount LED's under it. I am also mounting it with standoffs, so the glow will come through the letters, and around the perimiter. I sent my my waterjet guy the CAD drawings that I made and should have it next week. I also put a little tab on the top bending down with arches cut into it to act as a plug wire seperator too. Can't waint, should be pretty nice!

 

[jdxnc]

Nice idea, I have a laser at work, think I'll make myself one!

Edit:

And there we go, prototype is done(on scrap). Now that I know fitment is perfect, I get into making it more stylish.

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[2gSpyder4g64]

Nice idea, I have a laser at work, think I'll make myself one!

Edit:

And there we go, prototype is done(on scrap). Now that I know fitment is perfect, I get into making it more stylish.

Looks really nice,

and heres an update on mine,

After 3 months of use, it started warping and it got a little brittle,

I decided to cut it again, with fixed bolt hole positionns, but this time i used a 6mm sheet, it looks really nice and not so cheap like the past one.

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(the one sitting on top of the bov is the new thick one)

and i also made a few maore and gave them to my friends haha

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IF anny one wants to a copy, here is the autocad drawing tapa acrilico 6mm.dwg