Po' Mans $20 radiator cover

[vert]

Since I am going to do my cam install soon, I thought I would work on some appearance mods in the engine bay. I bought $15 sheet HDPE and $5 for the clips, then I made a template out of paper, traced it to the plastic and done. I really did not want to spend $160 bucks for a V6 radiator cover and this only took a couple hours max..

[SRG963]

Nice! Polyethylene high-density weighs less than the metal ones, and doesn't absorb any heat.

Wanna make me one for my Rotofab?

[WickedMom]

Looks awesome.

[jcmGT]

FYI- HDPE starts getting soft about 125C - not sure what the max under hood temp is.

[vert]

It will have to get up 230* before it will get deformed. If it warps, it wont take me long to make another one out of a polymer.

[-Ray-]

Nice work Chris.

[norm8332]

I like it. Where did you get the hdpe sheet and clips? Hope it holds up!

[vert]

Menards which is similar home depot and the clips came from autozone.

[MIEngineer]

Nice!

The holden one is fine, until you go to anything but a factory intake.

[travis gore]

looks GRRRR8!! nice job

[tchr49]

Looks great!
Any plans to make more?

[Bear]

Looks absolutely great. Love it!

[jscruick]

Did you score the poly with a utility knife, or reverse a Skill saw blade?

[locrzn#92]

Looks great.

[MongosG8]

Came out great!! Ingenuity at its best!

[I12XLR8]

Awesome! Must be tough to top up the washer fluid though...

I'd also be interested to know what you cut it with; it looks very clean.

[vert]

Did you score the poly with a utility knife, or reverse a Skill saw blade?
My skill saw had a metal blade in it so I thought I would give it a try and it worked. I really thought it would melt or fuse the cut back together, but it did not. It did leave melted pieces on the edges and all I did was scrape them off with a utility knife. I also used the utility knife to trim any tight areas around my intake. I also used a round grinding stone to shape the inner corners.

[vert]

Awesome! Must be tough to top up the washer fluid though...

I'd also be interested to know what you cut it with; it looks very clean.
The cover is actually 2 pcs so it makes it easy to remove, it is just 2 clips and it slides out from the third clip. The center of my intake is where the 2pcs butt together under the clip.

[DCC Justin]

What does it clip on to? What type of clips did you use? I'm think about trying to make this work with my rotofab/tvs.

[STL_G8GT]

My skill saw had a metal blade in it so I thought I would give it a try and it worked. I really thought it would melt or fuse the cut back together, but it did not. It did leave melted pieces on the edges and all I did was scrape them off with a utility knife. I also used the utility knife to trim any tight areas around my intake. I also used a round grinding stone to shape the inner corners.

It looks great, and once you put it through its paces with endured heat, ill give it a go!

[vert]

I thought I would post this up to give some a better detail on how I made them.
At the front of the radiator support, you will see a ridge that runs all along the front of the radiator. Along this location there are 5 areas that you will insert the clips into.
*The first pic shows the starting point for a template. Continue to add paper until you have the desired look/shape you are wanting. Tape the paper down to the bumper cover and then press the paper into the ridge to get the curve and angles. Once you have a crease along the ridge, take a marker and follow the crease.
*The second pic shows after I cut the template out by following the marker lines. After you test fit the template, I placed oil on the radiator cap to marked where the opening needs to be for the cap. I also marked the openings for the clips by pressing the paper down into the hole and then I put a hole in the center of the opening. I then cut out the openings with a utility knife and be sure to test fit the template to make sure the holes line up.
*Transfer the template over to your desired material and cut the material out. I used a saber/skill saw with a metal blade. I am sure a blade specifically for plastic would be better, but the metal one worked. Test fit the cover, trim off areas that are tight and shape the corners.
*Once the cover fits, you can trace the openings for the clips and radiator cap. Place the template over your cover and trace out the opening. WARNING>>>If you altered the shape of your cover vs the template, your openings could be off, so double check.
* I used a 2 3/4" hole saw for the radiator cap and 5/16" drill bit for the clip openings. Test fit the cover after you have made the openings and if all is good sand down the edges.
* The last 3 pics shows the ridge line, the opening for the clips and the clips. I purchased the clips from autozone and they 1/4", but I think 5/16" clips might hold better.
Today, I drove the car for an hour straight and so far so good. We will see what happens once it heats up outside.
1392113922139231392413925

[todds87ss]

Looks great. If it fails to hold up under heat, you have a great template for a 16 gauge sheet steel version.

[SpeedRacerX]

Nice! I might do this as that area under my hood looks bad.

[Panzer Leader]

That looks GRRRR8!!!!

[MAYBEN]

looks great!

[AVIDMOTION]

i like it, sell a kit and I am in!

[GT Drew]

Good work. We don't have to depend on the aftermarket to make everything.

[Kermit]

:bump: Wondering how this is holding up with all the heat we have been having this summer?

[vert]

Heat? Do you mean 105* and no rain for 7 weeks as being hot? I can take a pic to show it is holding up.

[vert]

Here is an updated picture. I really think that the material is pliable enough that if it did warp it goes back into shape. I know I need to repaint them since I scratched them up during my cam install. On a side note, I hope to finish my engine dress up once it cools dow
n.

[SBM-09]

Looks awesome! :)

[SpeedRacerX]

Here is an updated picture. I really think that the material is pliable enough that if it did warp it goes back into shape. I know I need to repaint them since I scratched them up during my cam install. On a side note, I hope to finish my engine dress up once it cools dow
n.

Unless I missed it, is this the first time in this thread you mentioned you painted these? Because I have been going nuts trying to find this material near me already in Black. I finally found clear/sort-of-clear and thought I would paint it black but was wondering how it would hold up.

If you painted, what did you use? Something high-temp?

[AVIDMOTION]

Could I get a template like that from one of you guys whom has already done this?

[vert]

Unless I missed it, is this the first time in this thread you mentioned you painted these? Because I have been going nuts trying to find this material near me already in Black. I finally found clear/sort-of-clear and thought I would paint it black but was wondering how it would hold up.

If you painted, what did you use? Something high-temp?
The original material was also black, but it had luster to it so I painted it. I first used plasticoat, but I plan on repainting them with a flat spary paint.. I scratched the plasticoat throwing them around in my garage during my cam install.

[adamsar]

Nice, I think Im going to have to borrow your idea if you dont mind....