Valve Covers - Weights of Cast Aluminum & Stamped Steel Covers

[Darrel Starr]

Bill Rusk asked for a weight comparison in a previous thread

Stripped Cast Aluminum Covers -- 29.3 oz for four.
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Powder Coated Cast Aluminum Covers -- 29.6 oz for four.
P1170005.jpg

Powder Coated Stamped Steel Covers -- 22.8 oz for four.
P1170014.jpg

The Stamped Steel ones are 6.8 oz (23%) lighter which makes sense since aluminum weighs one third of steel of the same thickness but the aluminum ones are more then three times the thickness of the stamped steel ones.
I still like the aluminum ones!
Submitted by the Weights & Measures Division of Starr Aero.

[bushmaster]

Where do you get the chromed steel ones

[Darrel Starr]

I don't know if anyone is selling the steel ones chromed. When I wanted chrome covers for the Continental engine in our Cessna 120, I took a set to the local chrome shop and had them chrome the outside only. You don't want the possibility of hard chrome flaking off inside the engine.

[mike mcs repair]

Where do you get the chromed steel ones

http://www.caswellplating.com/ set=up and do your own..... (I am always looking for an excuse to learn a new thing for my shop) they have cool anodizing kits too! (unfourtunately I have trouble ordering from them to Alaska because of shipping restrictions on some of the caustic chemicals.. grrr)

[jk]

Did mine in gold tone, just to remind me how much it cost to rebuild the motor.

[Bill Rusk]

Thank you Darrell. A good and most excellent report. I guess I will do the lightweight units. I do like the cast ones though.

Bill

[jgerard]

The comment about chroming the inside is very true. I have seen chrome flake off the inside of valve covers before. They looked great on the out side but were horrible on the inside. Having them Nickel plated is another great idea instead of chrome.

I took an engine apart that had been sitting out side for many years near the coast and every part that was chrome was rotted about 10-20 times worse than the other cad plated or steel parts. Some of the push rod tubes where rotted in half some of the push rods were even rotted in half. The intake tubes were toast along with all the valve covers. Nothing that was chrome was re-useable. Not that any of you would ever let your bird get that far gone



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Jason

[aktango58]

two day annual on that one?

[Steve Pierce]

ECI used to make stainless steel covers that were really nice and trouble free but for some reason they are no longer available.

[sierra bravo]

If engine appearance is your passion you can get custom billet aluminum valve covers at www.secustomairboats.com

http://www.secustomairboats.com/JURN...TORS%20002.jpg
http://www.secustomairboats.com/JURN...TORS%20008.jpg

[Darrel Starr]

Those covers are great but not PMA'd so I can't use them on my certified plane. About a year ago, I emailed this outfit to see if they would be interested in making replicas of the old cast ones & I would work withthem to get them certified but I didn't get an answer.

[Steve Pierce]

The nice thing about the stainless ECI covers is they don't rust which is a problem with chrome and paint and they look good. Ever look at the condensation inside a valve cover?
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Note the rust on the valve spring and seat along with the condensation on the nut and rocker arm.
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[sierra bravo]

Those covers are great but not PMA'd so I can't use them on my certified plane. About a year ago, I emailed this outfit to see if they would be interested in making replicas of the old cast ones & I would work withthem to get them certified but I didn't get an answer.

Darrel,

The FAA rules provide us with alternatives yet most owners abide by restrictions. Here's an article that should help.

http://aircraftrebuilder.com/index.p...tent&Itemid=29

I'm completely happy with my stamped steel/gray painted covers. Rust on the inner surfaces is the least of my concerns. Rust on close tolerance parts worries me more. But for guys like Bill who are building experimental? Those milled aluminum covers sure are pretty. And it looks like you can specify the engraved text. That could be fun in itself.

Here's another option for valve covers. http://d30045064.purehost.com/RockerCover.html

SB

[Darrel Starr]

Sierra-Bravo -- here is an exerpt from the aircraftrebuilder document you mentioned:
If we cannot find PMA, TSO, standard, or production holder replacement parts, we are left to
make the part under the owner produced option under section 21.303(b)(2). However, we must
remember that the part is for the owner/operator’s aircraft only and is not manufacturered for
sale to other TC aircraft.

However, in the case of valve covers, there is no problem finding PMAd parts so I don't think there is any way to justify "owner produced" parts.

[sierra bravo]

Can you find them in non ferrous materials? I don't really care about valve covers but if I did I wouldn't hesitate to play the game and get aluminum ones. Or try, at least.

[jk]

Holy cowwa bunga, look at all that H20 in Pierce's photo's. I would think that that would evaporate instantly in the hotter than hell blast furnace of Texas.

[mike mcs repair]

....there is no problem finding PMAd parts so I don't think there is any way to justify "owner produced" parts.

custom aluminum ones??
I think It would fly just fine FAA wise.....

[Darrel Starr]

Mike - I would like to see a variety of custom aluminum ones available for certified aircraft. Are you saying that you think the STC process would be relatively easy to accomplish? I have been assuming that this would be difficult.

[mike mcs repair]

Mike - I would like to see a variety of custom aluminum ones available for certified aircraft. Are you saying that you think the STC process would be relatively easy to accomplish? I have been assuming that this would be difficult.

no, owner produced part.... you dream up what you want for YOUR plane, and make it or have it made.. with in reason.. then that brings us back to that field approval thread, been out camping for the week, any news on that yet?

[skywagon8a]

Mike - I would like to see a variety of custom aluminum ones available for certified aircraft. Are you saying that you think the STC process would be relatively easy to accomplish? I have been assuming that this would be difficult.

Darrel, Having been through an STC process or two, I would think, that if you were so inclined, that acquiring an STC for cast or CNC machined aluminum rocker covers would be relatively easy. The process is directly proportional to the complexity of the product which you wish to produce. Since, as I understand it, you have an engineering background this would be a fairly simple project. It is only one part which is not highly stressed nor does it perform any function other than keeping the oil from falling out of the engine. My opinion is to go for it. Find a local machine shop to work with. They would probably love to make a bunch of airplane parts and you may find that the cost, with volume, will be rather surprisingly low.

[Darrel Starr]

Thanks guys, I will give it some thought. Everytime I get excited about something like this I pause and think of the potential liability issues. Just defending yourself from a frivolous law suit could be devastating - that is the point where I then backoff. Putting the family finances in jeopardy for a hobby thing is not a reasonable path. I know a couple of guys who work on the unlimited racers at Reno just for fun -- they were sweating bullets after last years tragedy waiting for the litigation to reach them; not a good feeling.