Ok, starting with the Timing Cover since it was the longest ago project. Sorry for the long thread and the out of focus pictures but this is archivial stuff and I don't want to take it apart again.
What I started out with was a pile of 3 Buick timing covers with the need to make 1 that would work on my motor in the frame and I wanted a gerotor pump over the stock wear prone spur gear unit. One stock V6 cover with a hole knocked in it, a stock L36 (FWD 3800 Series II), and a Stage II racing dry sump unit from a local guy who runs a 6-71 supercharged Stage II V6 in a rail. I don't have pictures of the original covers before the cuts but what I end up with was the bottom (oil pump) section of the L36 cover and the top half of the Stage II cover with around 1/4in overlap. The original plan was to weld them together so I made a jig out of 1/2in steel plate that I still have sitting around should I need it but since I had the overlap I decided to just fit the 2 together and use a combination of epoxy to build up low spots and grinding to make a joint that I could seal with aviation form a gasket.
Here's how it went together:
Lower section on the block
That fitting you see sticking out is the oil feed into the block since the oil passages don't line up because of the lower deck height on the FWD Series II block
Here you can see the backside of the L36 oil pump and the gerotor passages, note the notch on the right side
The side of the upper Stage II section notched to fit over the corresponding notch in the previous picture
Whole backside of the upper section, yes it's upside down
Right side overlap joint while the JB weld is curing
Left Side
I used the painters tape to keep it from sticking to the block or the other piece of the cover. The gap left after I peeled and sanded it off was for the aviation form a gasket to fill. You can see the gap across the middle caused by the different heights of the covers. Here's how I fixed that:
You can sorta see the spacer propped up between the sides of the timing cover, you can also barely see where I ground out the back of the timing cover to get the piece to sit flat. It's held in place by two 1/4-20 bolts and sealed against the cover with JB Weld.
Shows how tightly I got it in there, I did this all with a dremel and a high speed cutter
Here I've filled the oil passage that would take the oil back from the filter adapter to the block with epoxy. Its solid 1/4in thick and I sanded the flange flat with 400grit on glass using sharpie as a guide coat to find the low spots.
Unfortunately I don't have pictures of the intermediate steps of grinding that spacer bar to it fit the profile of the top of the lower section but lets just say I burned my dremel up (literally it caught fire) doing it.
What I started out with was a pile of 3 Buick timing covers with the need to make 1 that would work on my motor in the frame and I wanted a gerotor pump over the stock wear prone spur gear unit. One stock V6 cover with a hole knocked in it, a stock L36 (FWD 3800 Series II), and a Stage II racing dry sump unit from a local guy who runs a 6-71 supercharged Stage II V6 in a rail. I don't have pictures of the original covers before the cuts but what I end up with was the bottom (oil pump) section of the L36 cover and the top half of the Stage II cover with around 1/4in overlap. The original plan was to weld them together so I made a jig out of 1/2in steel plate that I still have sitting around should I need it but since I had the overlap I decided to just fit the 2 together and use a combination of epoxy to build up low spots and grinding to make a joint that I could seal with aviation form a gasket.
Here's how it went together:
Lower section on the block
That fitting you see sticking out is the oil feed into the block since the oil passages don't line up because of the lower deck height on the FWD Series II block
Here you can see the backside of the L36 oil pump and the gerotor passages, note the notch on the right side
The side of the upper Stage II section notched to fit over the corresponding notch in the previous picture
Whole backside of the upper section, yes it's upside down
Right side overlap joint while the JB weld is curing
Left Side
I used the painters tape to keep it from sticking to the block or the other piece of the cover. The gap left after I peeled and sanded it off was for the aviation form a gasket to fill. You can see the gap across the middle caused by the different heights of the covers. Here's how I fixed that:
You can sorta see the spacer propped up between the sides of the timing cover, you can also barely see where I ground out the back of the timing cover to get the piece to sit flat. It's held in place by two 1/4-20 bolts and sealed against the cover with JB Weld.
Shows how tightly I got it in there, I did this all with a dremel and a high speed cutter
Here I've filled the oil passage that would take the oil back from the filter adapter to the block with epoxy. Its solid 1/4in thick and I sanded the flange flat with 400grit on glass using sharpie as a guide coat to find the low spots.
Unfortunately I don't have pictures of the intermediate steps of grinding that spacer bar to it fit the profile of the top of the lower section but lets just say I burned my dremel up (literally it caught fire) doing it.
