I just started replacing my old engine valance with one made out of
aluminum.
I bought some template earlier on ebay. Not quite the same as the original. After I removed it and made the alum match the old valance I discovered the PO had bent the
cardboard around the suspension, so the alum need more cut out I use the template to cut out some more area.
I did not have any metal bending tools. Used a vise to bend along a line then a hammer to press the folded Alumium. I did buy a Harbor Freight power nibbler. Cuts like butter. I folded 3 sides and the bottom is just cut.
The interesting thing is how different the Ebay pattern was from what was installed. I wonder if they differ by year, Calif model, etc. or modified by PO. When I finish I hope to have a secure mounting point for Weber return springs, fuel supply and vent hoses etc.
To prep the Aluminum I wiped it with acetone then sanded with 400 Grit
sandpaper. Then I primed with etching primer and painted with 500 D Engine
paint. I used stainless bolts and screws to finish the installation.
