Clutch casing cover advice


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redeye
redeye
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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:



Do you think there is any chance I could get the wax to conform nicely over this or would I need to cut in strips? 

I figured I'd try and get it to conform but may struggle, maybe you guys will set me straight in the correct direction if it isn't even worth trying and wasting the wax (not at all cheap here).

Regarding using strips, should I cute them and lay them down adjacent to one another and then fill in the gaps with clay/putty and then finally cover in cling film perhaps before taking the mould off this? Obviously i will fillet the point where the cover meets the flange of the plug. Regarding filleting wax, I havent been able to find any where I am, will I be able to make the modelling clay work here or should I look for plasticine? MMM, wonder if my daughter play dough will react with the gelcoat BigGrin

Thanks in advance for any and all comments and help.
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redeye
redeye
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f1rob (12/06/2015)
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


Hey, thanks for the reply. So you say it'll conform nicely in one piece. I think I get what you're saying, but that would leave the mould 3mm shy of the fixing lugs. I was actually considering raising the cover off the mounting plate/flange and to get a mould that is a little longer than necessary to allow some trim off (if that makes any sense).
GO

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