Hot Rods Custom made valve covers

Got a few “likes” on the pic in the “Sexy valve cover” thread... and so thought I would give a bit of insight as to how it was made. This is an “Akron-Hed” for a Model T Ford. Made by Harry Halverson (engines by HAL) in 1926.

I made the valve cover from 3 sections. Basically top panel and bottom rail were machined from solid 6061 aluminum plate, and the vertical wall is a piece of formed 6061 strip to match the profile. The formed strip was done in 2 pieces to make bending easier.

Fabricated valve covers always look ugly to me... mostly the flat top and lack of compound shape I think. So the top panel was designed to have 1/4” of crown in the panel, and figure 8 recesses for the spark plug tubes to seat against. The panel is fully CNC machined inside and out. With large bend radius around the edges.



The bottom rail is made the same way, and includes small side bumps to cover the head bolts.



All weld joints are V grooved 3/32”, side wall thickness is 3/16”. I cut 1/8” strips of .060” 6061 aluminum sheet in the stomp shear to use for filler material so that no weld shadows would be visible due to material changes.




I kinda like it smooth... but I figure if I want something else... I’ll just cut the old one off and make a new one! Maybe deep fins...? Or a big HAL logo...?

 

Very nice! , I like that it is metal finished and polished rather than exposed welds. Don't get me wrong , I love to see the "row of nickels" from a skilled welder but an old head like that wouldn't look right.

 

Nice work. I have made a valve cover. But I wouldn't want to post it here or anywhere.

 

Nice idea and execution.

Welcome to the HAMB.

-Abone.

 

Nice work, Kevin

 

That is the “cherry” of the fab valve covers. I am with you on unpleasing look flat/welds showing .

 

VERY cool, can we see the inside?

 

Awwww... sucks fellas!

Sad thing is... the valve cover was the easy part! Here’s a few pics of what goes under the cover...

 

I didn't make this cover, but I modified it because I didn't like the "Power by Ford" logo that was pressed into the steel (I drive a 1952 MERCURY, not a Ford)
My father had access to a 4kw Amada laser cutter at work, so I spent an evening converting a bitmap scan of the Mercury logo into radiuses and straight lines, then we cut the logo and a backing plate, spot welded them together and brased them to the Valve covers.

Rune Waltoft from Norway

Sent fra min S52 via Tapatalk

 

I'm liking that smooth look. It looks like what a guy working in the Miller or Deusenberg shop might have turned out to use on his T powered car.

 

I must have schetched 50 designs before I threw I’m my hat and went smooth... but I really like it

Not too bad for a hair lip in his garage... eh?

 

Holy shit, those rockers are awesome.

-Abone.

 

Here is an original ad for the Akron-Hed...



You might notice the complete lack of a rocker cover... or even ROCKERS!!! Ball bearing filled tubes were to actuate the valves with this design. The tubes failed... duh! We’ll see how the rockers hold up...

 

Are these rockers actually machined from solid stock? If otherwise, can you explain how you made them?

 

You’d betta believe it!

That pic shows the progression of operations from 3” diameter solid chromoly steel. First to the CNC lathe, then a 4 axis CNC mill, and finally back to the CNC lathe to cut off the handle and bore for the bushings. Was a fun project... only took about 40 hours to program, and 4+ hours each to machine...

 

In the old days, they would use a stick welder and angle iron. Your way is better.

-Abone.

 

Compliments on your workmanship. I think you did a fantastic job. In my younger days I did some machine work for a few friends. They didn't understand that the set-up time was crucial to the end product. When they offered to pay me, I told them that they couldn't afford it.

 

Great. Now I'm going to have to set up a 4th axis on my mill.

Nice work by the way.

 

AMAZING! Nice work!!!!!!!!!!!!!!!!!!!

 

I came across this Haas HRT-210 pretty cheap... it’s worn out... but is good enough to support my habits. It’s wired thru an external M code, and a remote controller box. Then I found a worn out Haas HA5C... so had to get a dual controller box and couple the two units

Here she is set up for drilling spoke holes in one of my new Buffalo wire wheel centers

 

Dang. Just...DANG!

 

Here’s a shot of the innards... I didn’t worry about full weld penetration. There’s a number of places that the weld sagged thru, and that’ll be good enough to hold er together. The rest of the welds were V grooved, and so they just needed to hold oil back and polish up nice



In hindsight... I woulda just cut the whole darn thing from a solid block! The welding caused some distortion, and grinding always sux! But I made 2 covers, and they both turned out nice. So I’m not complaining!