View Full Version : Spark Arrestor cover upgrade

03-30-2010, 06:14 PM
So! That neat looking cover of the spark arrestor is busted and bent. I figured I'd upgrade it with something new.

I pick up some 16 gauge stainless and figured I'd bend something up and this is what I have so far.

I used the old cover to make a pattern.


Then unfolded that and traced it onto the stainless.


And plasma cut the rough shape. I then used my bandsaw to cut the pattern out.


03-30-2010, 06:14 PM
I had to get creative with the metal break.





03-30-2010, 06:15 PM
A test fit to the motor.



I cut out some pieces to weld to the top, kind of trying to replicate the stock look a little.


03-30-2010, 06:19 PM
I'll tig weld up the seams tomorrow.

I'm not sure at this point if I'll polish it or get it powder coated to match the valve covers.

03-30-2010, 06:56 PM
OMG! This is so awesome! It really makes me want to learn how to weld and work metal like this. Looks like you'll have a great final product. Just working up the template is quite an achievement in my book. Thanks for sharing/inspiring!

Double D
03-30-2010, 08:44 PM
Mass produce and sell. :)

03-30-2010, 09:28 PM
I'm not sure at this point if I'll polish it or get it powder coated to match the valve covers.

Depends on how good your tig welds are... ;)

Going to leave the weld beads or smooth them out?

I'd powdercoat...

03-30-2010, 09:34 PM
Depends on how good your tig welds are... ;)

Going to leave the weld beads or smooth them out?

I'd powdercoat...

Self taught, but not aircraft frame good.

When I ask my wife about it, she said is there anything else chrome looking on the motor? Good point. I think my welds would stand the pretty test but I don't think it would look the part, really.

The next step is, can the powder coat guy match the factory blue on the valve covers?

03-30-2010, 09:39 PM
And another wrench in the mix.

I really wanted to do this in carbon fiber so this might just turn out to be a plug for a mold to make that happen.

Who knows at this point?

03-30-2010, 09:39 PM
92Maristar, Looks great nothing better than making you'r own part's by hand.

03-30-2010, 10:30 PM
That thing looks awesome. I'd buy one if you were selling. Is there any way you could e-mail me a pdf of the template, or a picture of it from straight down?
I'd like to try to make one, is there any reason you wouldn't use 1/16 aluminum plate instead of stainless? If I have it powder coated I don't think it would matter.

03-30-2010, 10:41 PM
It looks great. Do what you want.

03-30-2010, 10:45 PM
Brush it up and clear powder coat. :D

03-30-2010, 10:53 PM
You might be better off powder coating as close to the valve cover blue as possible, then color matching paint to to repaint the valve covers. Great work so far.

03-31-2010, 05:58 AM
You might be better off powder coating as close to the valve cover blue as possible, then color matching paint to to repaint the valve covers. Great work so far.

Well as you can see the valve covers are kind of worn out. If I go with powder I'm thinking about taking the valve covers in as well.

03-31-2010, 05:59 AM
As far as selling them, It might be costly for me to put the time into them. I'm not so sure people want to spend that kind of money on such an old boat.

Truth be told, I made it out of stainless because my first thought was to polish it. Once you polish stainless it holds that shine a lot longer then aluminum.

Kevin 89MC
03-31-2010, 02:16 PM
Nice job so far! Looking forward to seeing the finished product.

04-01-2010, 09:42 PM
I got the tig welds done today. I'm just to drunk at this point to post the pics, tomorrow for sure. I just so tied up wiht other stuff right now. Windshield frame is cracked and I don't like that at all!!

04-02-2010, 08:04 AM
I still have to do some clean up work and then I'll figure out a finish. I might try a brushed finish first to see how that looks. If I don't like it I go polished and if I don't like that I'll have it powder coated.



04-02-2010, 08:15 AM
Grind down the welds to clean them up and send it to one of the best in the country for polishing, Specialty Polishing, http://local.yahoo.com/info-13030423-specialty-polishing-winston-salem

04-02-2010, 01:21 PM
Well done, looks good! Wish I had your skills! Can't wait to see the finished product. I think polished would look good, but so would matching? Tough call.......

04-02-2010, 02:25 PM
Are you sure it's going to hold up???? :)

Great job.


04-02-2010, 03:35 PM
Tim - Looks fantastic. I may have to stop by sometime and have a go with your plasma cutter. I have been wanting one of those pretty bad. I am tired of wearing out cutting wheels. Good work though. If I were you I would grind down those welds and polish that bad boy up, OR put it uder a drill press and give it a jeweled finish. Now that would be different and awesome. Anyhow, it will certainly look better than the old plastic one no matter what you do. Look forward to seeing you on the lake some time. Mark.

04-02-2010, 03:52 PM
I like that a lot. I WANT ONE!!!!:D

04-02-2010, 04:24 PM
As a matter of fact I have looked at this over the last 30 minutes and just dont have the shop or the right tools to make one. I really would be interested in one and really like what you have made. I think that if you polish yours it will be a bear to keep looking new but it is going to look great. I would also condider powder coat, it may be easier in the long run.

Please PM me on the cost of material etc and what you would charge to make me one.

04-02-2010, 06:14 PM
Mark, if you need metal work done give a call. I'm kind of busy right now, trying to catch up on boat projects but would help when I can for sure.

I think that stainless, unlike aluminum, holds a polish pretty well with less work. This is the main reason I went with stainless. That being said I'm pretty sure I'm going to take the valve covers off on sunday and then take all 3 parts down have them blasted and powder coated blue.

As far as me making them for other people, it would pretty costly. I've got a good bit of time into this. If I was a production shop with a CNC machine and some custom metal breaks I might be able to do them faster. If you really want one and don't mind paying for my time then send me the PM. Remember, it's close to summer and time is at a premium.

Here is what it looks like after some clean up.


04-02-2010, 06:17 PM
I need to talk to Jim about some 285 stickers!!!

BTW, I'm going to make a 2" 3/16" custom knurlled hold down bolt for it too.

04-03-2010, 05:01 PM
WOW!! Clearly, that is not your first rodeo, in the metal shop...that looks fantastic!

04-04-2010, 08:29 AM
Chrome it!!!!!


04-04-2010, 10:35 AM
Chrome it!!!!!


Metal has to be cleaned up, ground down and polished before the nickle and chrome plating can be done, so why go to the extra time and expense when it's basically already done and the finish is the same when done right.

04-04-2010, 10:45 AM
Polished stainless last forever and is easy to maintain.

04-04-2010, 11:29 AM
Drilled the mounting hole and final test fit this morning and I'm leaning back towards polished. :o


04-04-2010, 11:53 AM
Nice work!

I would say polished or brushed finish as a 2nd choice.

Why use stainless and cover up its beauty with paint or powder coat?

04-04-2010, 02:22 PM
Polished stainless last forever and is easy to maintain.

I agree!