Wog's '78 Wild Child build

From basic novice to the hard core cutomizing. Sharing tips, tricks and knowledge. Feel
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robin1731
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Re: Wog's '78 Wild Child build

#16

Post by robin1731 »

Are you going to leave the ends of those square? I would think a radius would be better.
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wog
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Re: Wog's '78 Wild Child build

#17

Post by wog »

Not square, those were just scraps to show the layered look I'm going for to match the engine guard angle.
I'll post up a rendering shortly of the fin shape.

Edit: Here's the top fin.
Valve cover fin weld on - top.jpg
Valve cover fin weld on - top.jpg (15.48 KiB) Viewed 287 times
The excess material is still shown. I'm thinking of using 3/16" thick alum and cutting 5 each 3/16" slots were the original Honda small "fins" were.
Then I can plug weld them from the back side of the cover. I would weld a full bead across the top fin and mill it down with a ball-end endmill.
Will probably also weld each end of the fin on the outside to blend it into the wrap around Honda fin if that makes sense.
Great to keep these old 'Wings flying on down the road.
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Re: Wog's '78 Wild Child build

#18

Post by Blubber »

Cool idea of the coolings fins, I was planning on doing the same:
Only I was planning on using heat sinks

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Things changed because of something Duke remembered
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Your approach will also work action1
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wog
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Re: Wog's '78 Wild Child build

#19

Post by wog »

Those are very cool! action1
The style I remember. Wonder how many were made.

I'm just now taking the first fin off the mill.
Update shortly.
Great to keep these old 'Wings flying on down the road.
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Re: Wog's '78 Wild Child build

#20

Post by wog »

Here's the trial slot in for the top fin...
(that ugly ground down weld will be covered and this is still just a prototype)
valve cover fins 016.jpg
valve cover fins 016.jpg (136.14 KiB) Viewed 278 times
And the profiled fin...
valve cover fins 017.jpg
valve cover fins 017.jpg (131.46 KiB) Viewed 278 times
I rounded the end of the fin instead of squaring out the end of the slot.
(simply because that's easier, and I'm lazy!)
valve cover fins 019.jpg
valve cover fins 019.jpg (125.86 KiB) Viewed 278 times
Here's the top fin in place, not sure if I'm going to go with one this deep.
Will need to see how it looks on the bike.
valve cover fins 020.jpg
valve cover fins 020.jpg (134.84 KiB) Viewed 278 times
Also, I think I'll make the 3 middle fins out of 1/8" thick stock to match the Honda fins better.
valve cover fins 021.jpg
valve cover fins 021.jpg (128.28 KiB) Viewed 278 times
Now, off to melt some aluminum! :flamer
Great to keep these old 'Wings flying on down the road.
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wog
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Re: Wog's '78 Wild Child build

#21

Post by wog »

I'll not surface cut down the fins as it left the center of the cover paper thin.
But I think this will work, but keep in mind, I'm still "Winging" it! lolol lolol lolol
Here's 1/2 of the down and dirty trial plug weld on the inside that will hold the fins and keep the cover oil tight.
valve cover fins 023.jpg
valve cover fins 023.jpg (123.06 KiB) Viewed 273 times
This is the ball end mill that I'll use to round off the weld on the upper length of the top fin to blend it into the cover.
valve cover fins 025.jpg
valve cover fins 025.jpg (125.85 KiB) Viewed 273 times
valve cover fins 024.jpg
valve cover fins 024.jpg (127.99 KiB) Viewed 273 times
And here's my gross attempt to merdge the fin into the Honda fins.
valve cover fins 026.jpg
valve cover fins 026.jpg (121.56 KiB) Viewed 273 times
Calling all (or any) mold makers out there......
Can you give me any hints on how to merdge or blend in the fins at the end?
PM me, I promise I won't tell. :-D
Great to keep these old 'Wings flying on down the road.
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Re: Wog's '78 Wild Child build

#22

Post by roncar »

wog wrote:I'll not surface cut down the fins as it left the center of the cover paper thin.
I remember hearing the later covers were thicker. Not sure by how much though. Here is one reference..

http://www.motoraction.com/story/index.htm
1977 saw the first tentative model changes based on customer feedback to Honda (hands up all those who can remember filling out those early questionnaires at rallies) and the Goldwing got higher handlebars with neoprene grips, dual contoured saddle and chromed heat shields on the header pipes. Chromed upper engine mounting brackets were a nice touch. More importantly, the steering head bearings were now tapered rollers instead of quick-wear & seize ball types. Front & rear engine and rocker covers were now thicker and this was designed to reduce noise, but no-one really noticed. The fuel tank had an internal coating applied to prevent rust.
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Re: Wog's '78 Wild Child build

#23

Post by wog »

Thanks Ron!
I'll check a few other covers I have.
Might be ok with any as I milled down that one thinking I'd need to have a flat surface, but with individual slots cut and plug welding, I think any will work.
Great to keep these old 'Wings flying on down the road.
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Re: Wog's '78 Wild Child build

#24

Post by Easter »

You said something in an earlier post about doing it an easier way because you were lazy. This definitely is not the project of a lazy man. I am enjoying following along.
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Re: Wog's '78 Wild Child build

#25

Post by sunnbobb »

If all the fins were welded in, you could then shape the joints using the roller end of a belt sander?
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wog
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Re: Wog's '78 Wild Child build

#26

Post by wog »

Haven't done much with this, but I did have an idea that will save me a lot of finishing time.
Instead of welding the length of the top fin, then ball milling it down and finally blending it in,
I'll just powder coat 'em!
Here's a cover that I had coated probably 15 years ago.
Aluminum color power with a clearcoat...
valve cover fins 027.jpg
valve cover fins 027.jpg (129.71 KiB) Viewed 220 times
I figured that if I could get the powder thick enough or maybe go with two coats, it would fill the slight gap between the slot and the fin.
I was just shootin' some other parts flat black and gave it a go.

Just sprayed...
valve cover fins 028.jpg
valve cover fins 028.jpg (138.39 KiB) Viewed 220 times
Came out great in a single heavy coat. dancr
valve cover fins 030.jpg
valve cover fins 030.jpg (113.45 KiB) Viewed 220 times
Here's a pic using a flashlight to highlight the angle.
valve cover fins 029.jpg
valve cover fins 029.jpg (128.15 KiB) Viewed 220 times
I will need to overcome what's called the "Faraday cage effect" to be able to coat in between the fins, but I'll preheat the cover first and shoot those areas with a small tube attached the the gun.
Maybe coat them with gold powder, then I'd really have gold wings! shakehands lolol
Great to keep these old 'Wings flying on down the road.
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Re: Wog's '78 Wild Child build

#27

Post by DocRoot »

Maybe coat them with gold powder, then I'd really have gold wings!
Gotta see that! :orange :orange
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Re: Wog's '78 Wild Child build

#28

Post by RonHolly »

Very cool thread! Like it with lot's of pics like you always do! Great work once again.
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Re: Wog's '78 Wild Child build

#29

Post by duke182 »

I could be wrong but I dont think powdercoating will work in the longrun
It occurs to me that over time vibration could cause small cracks that will allow leaks.
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wog
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Re: Wog's '78 Wild Child build

#30

Post by wog »

Good point.
The powder coating won't be the "seal" as I will weld the back side of all fins inside the cover.

Here's how I very precisely measured the angle needed to match the engine "guard". shakehands
valve cover fins 031.jpg
valve cover fins 031.jpg (113.4 KiB) Viewed 173 times
And the cut fins before removing from the tabs...
valve cover fins 032.jpg
valve cover fins 032.jpg (124.31 KiB) Viewed 173 times
Great to keep these old 'Wings flying on down the road.
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