TDI engine cover - ideas

Just taken. Needs a wipe over
397bd154d626631969cf3d25ba8d2621.jpg


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? ?.
OK here goes, the engine cover in the last photo, that is not from a A2 TDI.
So what we want to do know is, is it from a polo?
 
The problem is its started to crack at the right hand side where it drops down over the fuel pump.
I wonder if polypropylene would lend itself to a simple moulding? If it follows the original shape it needs to flex to fit it.
Another issue to overcome is the mounting points. Any plastic type material will need reinforcing to avoid wear to the mounting holes. Fibreglass springs to mind again as plates or washers could be moulded in.

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Yep they are definately A2 engine covers. When you change the colour from standard black all the detail shows through especially around the mounting locations. Ask me how I know?
 
audifan said:
Yep they are definately A2 engine covers. When you change the colour from standard black all the detail shows through especially around the mounting locations. Ask me how I know?
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Evening Graham,

Interested in seeing how you got on with what you’ve done with your factory engine cover.

What Bob has done looks good and I might do the same depending on where this thread goes.

I’m sure I would be able to lay some fibreglass on top of the factory cover to strengthen it followed by filling and sanding it until beautifully smooth then paint it. I’m sure I’d be able to get colour match HT paint, but does such a thing as HT filler exist or would ‘normal stuff’ be ok on the temperatures under the bonnet.

Happy to hear your thoughts as might give it a go whilst we see what this thread comes up with.

Kind regards,

Tom
 
Tom, HT paint not required as the cover sits proud of the engine and therefore has airflow over n under it. I used standard paints.

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Totally agree that high temp paint is not required on the fibre engine cover. In my case just got fed up with the black cover and decided to see what it looked like with a blow over of silver aluminium paint. No prep really done and the grain and flaws are visible, but that did not matter to me. I know you can get fibre reinforced filler but this also may be over kill as the cover does need to flex to fit around the air inlet pipe, the tandem pump and under the cabin cold air inlet. There is also the foam insulation between the rocker cover and the fibre engine cover again reducing any heat getting on to it.

Too dark and wet now to take any pictures but will do so some time tomorrow.
 
Jellybean said:
Tom, HT paint not required as the cover sits proud of the engine and therefore has airflow over n under it. I used standard paints.

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Thanks Bob,

That’s good to know sir.

I’ve zoomed in on the picture of your engine cover but not very clear as only in my phone right now. I’ll check on the laptop later, but my next question is did you fill it smooth or just primer and paint. I just can’t tell right now with the visuals my current device is showing.

What’s your thoughts on a few layers of fibreglass followed by filler/primer then paint and of course a layer of clear coat. If I was to have a go I’d want it as smooth as possible.

I’m so interested/excited where this thread might take us but also want to understand the possibilities of giving the factory cover a beautiful finish just in case this goes beyond where I’d like my wallet to stretch.

What you have already done looks good and I’m inrmterested in what Graham has also done in this region.

Kind regards,

Tom
 
2work said:
Thanks Bob,

That’s good to know sir.

I’ve zoomed in on the picture of your engine cover but not very clear as only in my phone right now. I’ll check on the laptop later, but my next question is did you fill it smooth or just primer and paint. I just can’t tell right now with the visuals my current device is showing.

What’s your thoughts on a few layers of fibreglass followed by filler/primer then paint and of course a layer of clear coat. If I was to have a go I’d want it as smooth as possible.

I’m so interested/excited where this thread might take us but also want to understand the possibilities of giving the factory cover a beautiful finish just in case this goes beyond where I’d like my wallet to stretch.

What you have already done looks good and I’m inrmterested in what Graham has also done in this region.

Kind regards,

Tom
Click to expand...
Hi Tom, yes it was several layers of high build primer and other spray paint I wanted to use up rather than throw away. Mostly acrylic. Problem is the engine vibration causes the cover to flex so have some cracking on corners.

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audifan said:
Totally agree that high temp paint is not required on the fibre engine cover. In my case just got fed up with the black cover and decided to see what it looked like with a blow over of silver aluminium paint. No prep really done and the grain and flaws are visible, but that did not matter to me. I know you can get fibre reinforced filler but this also may be over kill as the cover does need to flex to fit around the air inlet pipe, the tandem pump and under the cabin cold air inlet. There is also the foam insulation between the rocker cover and the fibre engine cover again reducing any heat getting on to it.

Too dark and wet now to take any pictures but will do so some time tomorrow.
Click to expand...
Thank you Graham,

Understood about keeping it flexible. I suppose I need to obtain a new/replacement foam item between the rocker cover and the engine cover before I start to play around.

I think there is a little bit of the foam part towards the back but certainly not complete as I have seen what it’s supposed to look like on 7zap. Next purchase I guess. I remember a thread some time ago stating that they are no longer available but didn’t pay much interest to it back then as I was a BBY user.

Kind regards,

Tom
 
Wrong they are available. I did a sort of group buy for them from Crewe Audi either earlier this year or last year.
 
If noise is a consideration then I guess a lead base foam covering on the underside would be best.

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@2work
Tom this was the thread

TDI top engine cover noise insulation?

Hi all, recently perusing the how to section with a view to eventually pulling the turbo and giving the variable vanes a good clean. I found a pdf which explains the process of removing the turbo, great! https://www.a2oc.net/community/index.php?attachments/tdi-cylinder-head-pdf.9058/ quick read...
www.a2oc.net www.a2oc.net
 
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