How to Build an Engine Cover

In specialty automotive scenarios like racing and restoration, the inclusion of aftermarket upgrades or performance improvements might include the covering of the outer engine compartments in order to prevent the viewing of engine parts, or for the protection of the driver in race conditions. Building an engine cover for any vehicle that has an engine depends more on the space where the engine resides than the engine itself. By covering empty space inside the engine compartment with an engine cover made of sheet metal, you create a clean look inside your engine's compartment that enhances the restoration and performance upgrades you have included into your restored or race ready vehicle.

Difficulty: Moderate

Instructions

Things You'll Need:

• Tin snips Sheet metal shaping mallet Sheet metal Drill Sheet metal screws Rivets Cardboard Marker

1. Create a template of the engine space that needs to be covered. Sheet metal is a rigid material but make sure to find an area of the compartment that can be connected from more than two points. In a classic car made in the 1970s, you will need to find connection points on the outer engine compartment walls and the engine itself. Utilize existing ground points like air intakes, or intake manifolds. You can also consider making an "L" bracket that can be secured using inner valve cover bolts as a securing point. To make the engine cover template, you will use cardboard pieces to re-create the empty space inside the engine compartment.

2. Make cardboard cut out pieces that match the shape of the empty space in between the engine compartment walls and the engine's air intake. Trace the cutouts onto sheet metal and cut the main pieces using tin snips. It is important to cut enough metal out so that you can "set" the piece after shaping. When shaping metal around corners, you can cut a "V" shape at the apex of the bend so the metal can be shaped properly. Many of these shaped corners can be used as secure points for the sheet metal to be attached to the engine compartment walls.

3. Shape the cut pieces of sheet metal using a shaping mallet. Use a padded base as you work the metal into the appropriate bends that match the engine compartment walls. Edge over the metal so when you set the cover piece in place, you have access to the lip when it can be secured to the compartment's outer walls. Using the edge over technique will give you a clean look when viewing the engine once the cover is installed. Continue to shape each piece until you have a complete engine cover once you connect all the pieces.

4. Rivet the pieces together by taking 2-inch sheet metal strips and riveting the joints together with two rows of rivets. After riveting, trim edges to insure a clean look after joining the seams. Use the rivets to connect the cover to any brackets that will be used to secure the cover to the engine (via valve cover bolts or intake manifold), and then secure the entire unit using the existing connectors and any new securing points you have created.

Tips & Warnings

• Sheet metal can be easily painted to match the current look of your car. Electric tin snips can make a big difference in the amount of time it takes to cut your pieces of sheet metal into the shapes you need.
• Do not cover any air intake ports with this engine cover. Any restriction of airflow around the engine may affect the way it cools itself off or how it burns the fuel in the engine. Restricting airflow in any engine can cause fatal damage to the components. Working with metal is dangerous. Always wear protective clothing and eyewear to protect against injury.