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Old 07-03-2009, 03:29 PM
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Default How To: shave your engine bay

In this how-to I am going to go through the steps that are involved in shaving an engine bay. I am only demonstrating on a small section for the time being. I intend on later taking out the engine and finishing but my wife is due in a month soooo... you get the point.

Update: Baby is here and healthy! Engine ready to be taken out. Progress soon to come. 11/27/09

This all can be done for as little as 300 (not including paint or your time).

-mig welder/ flux core wire - 180&up harbor freight (works just fine for this application)
-4 1/2" grinder & flap disc - 50&up lowes or harbor freight (the only reason for buying an expensive grinder is it will last longer)
-helmet - 18&up can be found cheap at most hardware stores (quick lenses aren't necessary only convenient)
-80,100,500 grit sand paper & bondo filler - 30 (shouldn't need more than a pint of body filler imo)
-gloves - you probably have a pair. They don't have to be welding gloves just something to keep your hands looking pretty. Long sleeve shirt is also advised as long as it isn't flammable

Of coarse you can go crazy and spend more on these supplies. This is just a basic list and will work just fine. If your not wanting to get too into the welding thing and want to save money. Then you can certainly find everything without breaking the bank.

Again the demonstration area is going to be small b/c of time constraints due to lack of time. So this will be the area worked on. The rest of the bay is the same process accept for the seam welds. Now is a good time to clean the grease and get things cleaned up.


Before you start welding you will need to expose the metal around the holes to be filled. I use an angle grinder with an 80grit flap disc. You only want to take off paint! That is why I prefer the flap disc over the hard disc that comes with you grinder. Yes, if you really want to save money (or get a great workout) you can just use sandpaper and some good'ol fashion elbow grease.
Please don't forget to wear eye protection. ***When grinding mild steel you DO NOT want metal to get in your eyes! The shavings have a chance of getting stuck and you will have togo to the hospital (they literally take a small drill bit and drill out the shaving b/c it leaves a rust spot in your eye)***


This is one of the reasons I <3 my DA!


Here I have taken the paint off around the holes to be filled. Just take your time and don't push the grinder into the metal or leave it in one place for too long.


This is my work horse. It's a miller matic 135 and can weld up to 1/4 plate if needed. I also use a gas setup w/ solid wire. The gas setup is more pricey but the weld ends up looking nicer and less cleanup is needed compared to the flux core. This setup costs about 800 but if you don't intend on doing much more than body work then a cheaper unit from say "harbor freight" will do just fine.


This is my speedglas helmet and copper tool I have made. The copper strip is put on the back of the holes to make it easier to fill and not burn through the edges while welding. This tool also helps make the back of the holes look better. Tip: wrap a piece of old leather around one end to make a handle. The copper transfers heat VERY well and this tool will get incredibly hot. Notice I covered the engine and everything that I don't want ruined with a cover. I just used a towel soaked in water. you can also buy a welding blanket if needed. Just make sure it's not flammable or it WILL catch on fire!!!


After welding it's going to look a little messy. Thats ok b/c we are going to go back over the welds with the grinder and clean everything up. **** When welding the holes up SKIP around! The sheet metal is thin and WILL warp if care is not taken.****


When filling bigger holes you can use a piece of scrap metal placed in back of the hole. I just used a small piece of metal strapping. On even bigger holes you can you can use a piece of thin gauge sheet metal that can be found at lowes & home depot.


Another pic. Everything filled in....


Next you want to grind off the excess weld material. Try to only take off what you don't want. Any gouges made here will have to be filled in with body filler later. When grinding down the welds you can use a heavier grit grinding disc. I still don't suggest using a hard wheel disc b/c it is way too easy to accidentally make a nasty gouge. If you only have a hard wheel then just be very careful.

If you run into hard to reach places you can use a dremel. The dremel will work great as long as the area isn't too big.




Now I go back and use a lightweight body filler. Then I sand with 100 grid sandpaper, put more filler on and finish up with 500 grit sandpaper.


Time to primer!!! If you find any mistakes you can easily go back and repeat the necessary steps were need be (fill forgotten holes, fix sanding marks or whatever imperfection you may not like)

I am going to leave it at that b/c painting could take a whole new thread.


Hope you enjoyed this thread. I will update in the future after my baby is born and I have time to finish.

I am not responsible if you ruin your car or weld your fingers together. If you are not confident in trying this, DON'T.

Feel free to post question or even pm me. Please keep the negative comments to yourself.

Thanks for looking!!!!!!

Last edited by Sam; 11-27-2009 at 09:35 PM.
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Old 11-20-2009, 07:26 PM
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it can be done without the copper if you use tack welds to build up the material but it is more time consuming.
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Old 11-22-2009, 03:14 PM
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Quote:
Originally Posted by obd1tuner View Post
it can be done without the copper if you use tack welds to build up the material but it is more time consuming.
Yes, the copper isn't nessecary but it can help in certain areas. Many parts of the bay can only be tack filled because of their location.

My engine is almost out so updates are soon to come

Disclaimer: This thread so far is just the beginning of "how-to shave an engine bay"!
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Old 02-02-2011, 02:13 AM
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cleaned
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Old 02-20-2012, 02:53 PM
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in for more
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Old 02-20-2012, 03:53 PM
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Lol op was in 2009 I don't think there will be more. Lol
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Old 02-20-2012, 03:57 PM
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Lol op was in 2009 I don't think there will be more. Lol
sucks when people give up on jobs.
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Old 02-22-2012, 06:43 AM
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Good write up. Great choice in beer as well!!
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Old 02-22-2012, 08:53 AM
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Either he decided not to post more...or his wife is 3 years over due with a baby
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Old 02-23-2012, 11:30 PM
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i'm actually curious as to what happened to sam he shaved my engine bay and did a damn good job on it too, then i gave him another integra, he got rid of the one in the pictures and fell off the face of the earth.. maybe his kid takes up of his time now but it would be good to know he's still around.. i think i'll have to text him when the hour is more decient
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