Hi guys, I am looking for some advice regarding plug making for a cover I will do for my clutch casing. I have worked out/estimated that 3mm will be pretty darn strong, so have gone and purchased myself some 3mm sheet wax and some modelling clay. The item I want to make a cover for looks exactly like this, not my picture,but this is it:

Easy to do,wont find many things easier to sheet wax !

First get a base board,make sure its 3mm thick.

don't sit your part on it thou,cut the centre out and place it over your main case sitting on all your fixing lugs

make it a tight fit

then cut a circle of wax out big enough to cover the whole case down past your base board.

place centrally an gently work down in all directions

cut out for a really tight fit on the oil filler housing-don't try to cover the filler yet

As you get to your base board comes the skillful bit ! Cutting it "just" to size

not to much so it ends up short of the base board and not leaving it too long so it bridges and forms a radius corner onto the base board,you want the wax edge butting to your base board perfectly

then I would make a small pattern the exact size of your filler boss to make it longer then cover the filler boss/pattern an butting up to the main wax covering

use heatgun/hair dryer to soften wax if needed

hope these ramblings make some sense

rob