So on this episode of 96blak54 projects we are performing an alternate solution to electronic fuel injection and ingnition timing by first figuring out a way to mount a distributor and be driven by the camshaft. After much collaboration with an ingenious, hands down super brain(lwarrior) this is what we came up with.
Now ideally, a fiberglass/composite type valve cover isnt really thought as stable enough for what im trying to achieve. An all aluminum valve cover makes better sense, but if you think about it, all the distributor is doing is spinning and no real tortion is being applied to where the structural of the valve cover is compromised.
If you notice in the 1st pic, i was performing the machine work with out any support to the front edge of the valve cover. Although the valve cover was adequate rigid enough while machining, i decided to hack up a front cover and then bolt it all up in a running scenario and then machine with a bigger tool. I will say it is very very very rigid. To be able to withstand the pressures of machining especially with dull high speed tooling is really good. My expectations with this project was failure and iexpected the valve cover to give out, break, otherwise fail, but to my surprise the rigidity of this was amazing.
You maybe asking. Why not just purchase aluminum valve covers and make things less complicated? Well i did. The aluminum valve covers are larger and not as conformed to the head like the composite covers are. If i were running a 4.6l this wouldnt be a problem, but since my duma$$ swapped in a giant wide 5.4l, their would be clearance for the brake reservoir or shock towers. It gets pretty tight in there!
As of right now, in its development stage, it looks like trash. Not much time was spent on presentable asthetics. What you see is a plate of aluminum on the front carved out in the shape of the cover bolted to an internal steel plate carved out to fit correctly, drilled and tapped and together sandwiching the valve cover material. Then mounted the head on the mill, camshaft installed, indicate the camshaft center line, then mount the valve cover and machine a hole for a distibutor to mount into and be driven by the camshaft. In the final results, those bolts wont be used, the bolt pattern has since been changed, and a thicker internal plate will be used along with socket style flat head bolts thatll be flush with the front plate.
A distributor still needs to be purchased and hacked up to fit. Ive found some cheap ones for $70 off ebay that looks like great candidates. Also a way to dial the dist and lock it down in place needs to be figured out. Its all a work in progress.
