Give a rocker a good ribbing!

[voodoo57]

As the escort nears it's final stage (at long last!) my attention is turning to the mk1 Tina estate, what i would like to know, is..... is it possible (i know most things are!) to make 1 rocker cover for the crossflow out of 2 steel covers, but to be a little different, such as (somehow) putting ribs/fins of some sort into the top, or, extend the lower edge a little way up so as to create a step but obviously not to cause an obstruction to the carb etc.... am i clear enough in my question? What are my options? has anyone done something like this in the past? can i have the cover pushed/pressed from the inside by high compression water jets or a punch of sorts? 

[slammage]

need to be careful that the base mounting flanges don't distort . if they do that's a world of oily pain. just make sure the rockers inside have plenty of clearance and abiding those two main rules.. the worlds your rocker cover related lobster

[voodoo57]

Haha! Slammage! such poetry! Yep, i have had a few other ideas as well, i am popping to the forge tomorrow and ask a few questions, got a couple of different ideas/designs in mind, watch this space!

[Deleted]

Yes you can have them pressed, but tooling for a one off would make it uneconomically viable.

[voodoo57]

Spoke with a blacksmith, he said the same, then... i had a thought! so i went to a metal fabricators, and will be having some shapes made that i think will do the job? I have decided to pull my finger out now and get on with as much as i can! i will update soon.

[voodoo57]

ok, so! what i done was make up a temporary design, then attempted to weld the parts in place! what a curse word! the rocker cover metal was so thin, i had to have a bit of power as the metal sections are a lot thicker, i ended up losing my temper, and had a fight with the rocker cover (with a large hammer!)
i went back to the yard today, and used another cover, now, it was very difficult trying to keep the welds to a minimum, and also difficult making sure there was no distortion, after messing about with grinders, and other mechanical machines, i gave it a second look, then shaved the oil filler tube off a bit to get a tight fit with the cap off a Triumph rocker cover, and still didn't like the exposed welds (a tig weld or two would have been better, but.... i don't have one!) anyway, i then realised i had a badge or two! so! my plan is.....
get this shot blasted (carefully) and powder coated, then try to clean up the old badge, or... see if i can find a better condition one (anyone?).

This is to go on the next project, being a mild custom on a mk1 Cortina Estate

comments and jokes are more than welcome!

[voodoo57]

My plan with the badge is to drill 2 small holes, then weld 2 threads on either side of the bars, then once slotted over the threads, fix 2 shiny nuts!

[colnerov]

Hi, Another method you could try is to use solid section as required and puddle weld through from inside the cover. Less distortion and no ugly welds, a wipe with a finger full of filler at the junction of the rib and the cover would produce a more realistic effect.

Colin

[voodoo57]

I have asked for a couple more rocker covers, and i will try your suggested technique, many thanks Colin.

[melle]

Should you run out of rocker covers to play with, you could send some money to Ireland and get a personalised cast alloy ribbed rocker cover in return: jrcast.com/?page_id=145

[voodoo57]

They look very cool! I look at my efforts, and think..... why bother?? however! I have a plan! (not a cunning one though!)