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can't imagine why you are flat broke....maybe if you concentrated on running gear instead of spoilers...... :). bet you are not too broke to buy a welder now tho!! :). you may want to try murphy auctions, i see welders ( albeit beat up ) go out of there all the time. should snagged one while i was watching. 300$ for a 300 amp pulsed mig power supply. that is about 10-15% of new. a lincoln 135+ is prolly the min you want to go. be sure to get infinite adjust power. cheapo units only have one or two sweet spots....thats why i dumped mine. it worked great on 1/8 - 3/16. but only at one rate etc. beyond or below that and it was a soldering iron or a cutting torch.
you could try some pop rivet thread inserts on the cover??. or even tee nuts split with a dremel and peened down on top to keep them from falling in. make your own brass inserts?? the only real issue i see is that the filler is on a lever arm and engine vibs will put a lot of g's on it, that of course relates to torque on the base. long term it will want to be revisited. even an additional collar or something? ext abs plastic cylinder with a disc to grab it at the 1" high mark?? probably a couple ways to buttress that. it is probably fine short term but man oh man if it busts on a trip you are SOL. could even and probably would, catch fire on the manifold...talk about a hot car at the autocross.
if you want to stop over some time i may be able to come up with some other ideas. maybe a dual split collar in a groove or something?? i can probably whack something out on the lathe that could bulletproof it. epoxy is ok but once it cracks it devolves quickly with oil and vibration. maybe even just couple of right angles stands?? a bipod support bolted to the cover bolts with a hose clamp?? you just want to make sure that the epoxy is primarily sealing, not solely standing up to vibration over long term in a difficult environment. i have a "plastic welder" (ala harbor freight) that could probably join some spot weld type things. epoxy and abs are not compatible and use a surface roughness latching .vs. a chemical bonding ala abs glues. that makes the bond the weak spot and stress will concentrate there.
just some ideas. love the concept. think i'll mod my extra cover in my copious spare time.
interesting approach on the head. it is def a bit of a weldup and the head would need destressing afterwards.
but what i really want to know is why you didn't do all this years ago so i could copy it before i decided to quit busting my butt on a car. :) it is a plot isn't it....something to try to force me back to the saab zone...
cya around.. maybe i'll catchya at scan west.
posted by 67.40.8...
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