Ouch!

I'm sure there's lots of ways to cut the Z engine cover to fit the Crawford Plenum. Here's how I did it.

1) Go slow. Cut oversize... sneak up on the final fit.
2) To prevent scratches, cover the powercoated plenum with a soft cloth and tape it down.
3) Make a pattern. Use the back mounting holes as your locating points. Use light cardboard or heavy paper stock and long 6mm bolts (10mm head) to locate and "mount" the cardboard flat across the front of the plenum. Mark and cut the pattern to fit.(This may take a little time and cardboard but it's certainly cheaper than new engine covers.)
4) Once the pattern properly fits the front of the plenum with the rear bolts in place, use the bolts to locate the pattern on top of the engine cover and trace a guide line (I used a black Sharpie).
5) Remove the pattern, verify the you can see the line and draw a second line 1/2" or so in front of the original line.
6) Remove the engine cover's gold colored retainers and rubber grommets. Note: The grommets are "directional".
7) Time to make the first cut on the second line. I used a dremmel and cut-off wheel and then flat and round files for final fitting. Note: Holding the cover in place for cutting was a trick for me. I used bags of lead shot. Sand bags should work almost as well. Becareful not to distort the engine cover.
8) Once the first cut is made, test fit the cover. It should still be oversize and you may have to re-mark the angles. Go slow! Continue marking, cutting and fitting. Eventually you'll be able to see the mounting holes through the engine cover openings. Use them as your guides.
9) Once you're close, reinstall the grommets and retainers to help in final fitting. Remember to leave about 1/4" clearance to allow for differential thermal growth.
10) That's it! Bolt your new Z Engine down... four fasteners, 45-57 in/lbs.

 

Dave, I'm confused, why would you cut the Z engine cover to fit the G? I thought that the Z engine cover will perfectly fit the G without having to cut anything.

 

By the way, I have the crawford plenum on my G.. So do I need to cut and fit the Z engine cover?

 

Vic,

Yes. Your 350Z Engine Ornament (cover) will require modification for use with any of the Crawford Plenums and probably the new APS unit. I don't know if mods are necessary with the Kinetix or AAM products.

To reiterate, the 350Z Engine Ornament (cover) will fit the G35 engine with the stock upper collector (plenum) in place. It should also work with Motordyne's 1/4" and maybe with their 3/8" spacer.

 

Vic,

You will need to cut either cover Z or G to fit a Crawford. Use the tracing method as mentioned earlier and cut short and make adjustments. Be careful if you use a dremmel at high speed as it will melt the cutline instead of cutting it. This is what i did over a year ago. It still looks the same. Take your time and you should be okay.

Happy modding . . . .

 

Can anyone offer advice on cutting a CF cover. I already made a template, but wanted to know if anyone knew what is the best way to cut CF? I was thinking of putting some masking tape down first then outline my cutline. Less chance of slip I would imagine and help give a cleanner cut. Also, and more importantly, what would be the best way to clean the cut edge of the CF? Epoxy? I am almost positive that is what is used to finish CF, but if anyone knows exactly what it is, lemme know!

Thanks!

 

Dave and Z, thanks for the info. However, as Diesel has mentioned, how to cut the carbon fiber engine cover? Is it going to be the same way as for the plastic cover? I have ordered a CF engine cover. So, tips and instructions on how to cut the CF engine cover will be much appreciated...

 

From my RC car days, I used a dremel with a cut off wheel, not a saw blade. Masking tape to cover the areas you don't want cut or damaged if you slip. After cutting I
apply some super thin CA glue (super glue) along all cut edges to prevent any fraying.
Just go slow, don't rush it!

 

WRX, could you please tell me more specific about what tools are needed and the size of the tools to cut the CF? Thanks.. I appreciate it. This is going to be my first experience, so I want to get lots of information so that I can do it right.

 

Vic,

I used a #420 15/16" Heavy Duty Cut Off Wheel with my dremel motor tool. Depending on your experience with Dremel electric tools you could use a single speed or a variable speed. I used a single speed with a foot activated variable control.

Check out http://www.dremel.com/html/home_fr.html and click on Accessories, Rotary Tool Bits, Cutting. You need a few of the cut off wheels since they do break. Although I haven't tried, there is the #542 Tungsten Carbide Cutting Wheel.

 

WRX,

Thanks alot for the information. Btw, is carbon fiber made of fiberglass? Do you think #542 will be better than #420? When you cut a carbon fiber, how do you smooth out the surface edge?

 

one more question, which dremel motor do you use?

 

It's a form of fiberglass. You can check out tap plastics. http://www.tapplastics.com/shop/sear...h=carbon+fiber

Anyways I have only used the #420 wheel, never the #542. The rotary tool I used is the 275 single speed tool with
the #221 Foot Speed Control and sometimes a flex shaft. After cutting you may need to sand/file the cut to be smooth,
then seal with the super glue.

Since I don't have the CF cover I can't tell you for sure how the cutting will go. Also
please be careful withe the dust that results from cutting CF. It's pretty nasty stuff
so I suggest you have a vaccum/shop vac handy.

Since you are cutting, try experimenting on the portion you aren't keeping to get
some experience cutting.

Disclaimer: This is only my experience, yours my be different, so do this at your own risk.

 

WRX,

Thank you very much for the detail info... I appreciate it

 

Your welcome. Good luck with you mod!