Problem of the day: In order to avoid using a hood scoop for additional clearance, I elected to lower the intake manifold about 3/16". The problem: That will require using the Ranger valve cover because its profile is about 1/2" lower than the plastic Fusion valve cover. That picks up another problem, the Ranger valve cover does not have provisions for a dipstick and the Fusion block does not have provision for an external dipstick. So I must modify the Ranger (aluminum) valve cover to accommodate the dipstick. First step, accurate positioning of the diptstick hole.
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The photo above is of the Fusion valve cover, lightly clamped onto the mill. The mill spindle is located over the dipstick hole by inserting a straight rod, in this case a transfer punch, into the hole.
The mill head is then raised, the Fusion valve cover removed and replaced with the Ranger head, which is clamped in place.
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The hole is then milled.
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The dipstick tower is machined of stainless steel and epoxied in place. I am very comfortable using epoxy for this job as the tower is well supported by the hole and there is no downward pressure, the tower sets on the base of the valve cover.
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The actual milling was done is less than a minute. Hours were spent on working out the location and holding of the cover. Days spent deciding on the proper action. The lathe work was straight forward and uneventful.
Bill