BigValve style valve cover for TOYOTA 4AGE 16V engine

[ralf]

I intall a 4AGE engine to my Lotus Europa. To get a classic look I made a new valve cover for this engine.
First I messured the cylinderhead and make a 3D Model and printed this to check the messurement.

[ralf]

Next I made a 3D model and tried to transfer the BigValve design to the 4AGE dimension. One oft the difficulties was that the 4AGE camshafts are belt driven which regular get a seperate cover for the belt. Because I want to get a similar design like the TC I choose to make the upper beltcover as a part of the valvecover.

[ralf]

For the sandcasting I need to scale up the model by 1%. Then I split the model in the inner and outer part. The outer part was filled and mounted to an old which can be mounted to the sandfilling mashine in the foundery company.

[ralf]

The model for the inside was also mounted to a plate. The models were fillered painted to get a better surface.

[ralf]

The foundery company installed the canals to cast the cover to the plate.

[ralf]

The foundery fix the plate to their filling mashine, put a frame to the plate and fill the frame with casting sand. The frame with the sand get removed from the plate. I was very lucky to find a foundery which still make sandcasting for privat people. Most of the founderys get bankruped in the late 1990th because of invirement expenses increased. The next days I will extend this post with the casting and mashining.

[lotusfanatic]

Hello Ralf,

 

That valve cover is superb! 

Mark

[TurboFource]

 

[Sandyman]

I just love to see the individual talents members bring to this forum. What a unique Europa we could put together if we got together. Ralf "Gut gemacht" thank you for sharing.
Sandy

[ralf]

Thanks,
the upper mold is put in top of the lower mold.

[ralf]

The two workers at the aluminium casting company put smelt aluminium into the mold.

[ralf]

After the aluminium is cooled down they put the mold to a shaker where the sand is removed.

[ralf]

The worker at the company cut the sprue and ballblast the cover

[ralf]

I don't make only one part, because I was scared to destroy some parts at the mashining and to equip the mashine has to be paid even if I make only one sample.

[jbcollier]

Very, very cool.  Well done.

For those of you with expertise in plastic printing.  Would it be possible to print just such a valve cover using high-temp plastics?  Perhaps add steel inserts at the bolt holes.  I know some some valve covers are plastic now but have zero knowledge otherwise.