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 Post subject: 2.3l Duratec valve cover
PostPosted: February 9, 2017, 2:04 am 
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Joined: January 18, 2015, 2:34 am
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Location: Los Angeles
I have a 2.3l with COP ignition. I have an hood interference issue with the oil filler on the high side of the cam cover. The cover is non-metallic. Am I correct in assuming it is made of FRP? Can I relocate the filler to the lower side and epoxy the repair? Anyone with experience on this mod? I really don't want to spend $500 on a special cover.


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PostPosted: February 9, 2017, 1:37 pm 
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These days many FRP parts like what you are talking about are made with injection molding. Since it's injection molded, it probably isn't polyester or epoxy plastic. I don't have any knowledge about the valve covers your talking about though.

Can you get a spare cover at a junkyard or something, even a piece of a cover to play with? As a fallback position, you could use a spare cover to cut out the pieces you want to make a cover for the old hole and get a filler neck with a flange of material around it. Then you could rivet this to the valve cover and use a sealant so you don't depend on a structural bond.

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PostPosted: February 9, 2017, 8:17 pm 
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How much clearance do you need? Any chance of sanding the filler cap to reduce its height?

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PostPosted: February 10, 2017, 2:02 am 
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I did shave the filler cap but I would need to relocate the filler neck to the lower intake side to make it work. Tom Carlin at Birkin sells a slick aluminum cover that is similar to the Raceline one but accommodates the individual coils ($485).


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PostPosted: February 10, 2017, 9:25 am 
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Could you trim down the neck on the valve cover and modify the cap so it would screw in just below the surface. Then epoxied the cap in place. Add a right angle fitting in the rear corner for filling? Dave W


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PostPosted: February 10, 2017, 7:09 pm 
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That's a possibility but I really need to lower the entire exhaust side as well.


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PostPosted: February 12, 2017, 3:18 am 
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I picked up this oil filler cap:

Image

If you were to completely remove the entire vertical portion, including the fillet, as installed it would sit just 0.3" higher than the top of the valve cover. That sounds like a lot of work for not much more than a 1/4 inch.

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PostPosted: February 12, 2017, 12:03 pm 
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Was there an aluminum valve cover for the Ranger or am I imagining things?

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PostPosted: February 12, 2017, 1:48 pm 
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There was, but it was not COP. No idea how it could but adapted to COP. I have an aluminum valve cover and a spare Fusion COP coil, so could easily do some investigating.

Bill


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