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Old 07-20-2003, 07:59 PM   #2 (permalink)
OthercarisaFiat
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Join Date: Apr 2002
Location: Chicago area
Drives: 92 TT,82 Fiat Spider
Trader Rating: (5)
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Materials you will need:
(1) 3/4" pipe nipple, 3-1/2" long not including threads (cut them off if present).
(1) Steel bar stock, at least 12" long (preferably 14"), 1" to 1-1/2" wide, 1/4" thick; or a channel if you can find it, 1-1/2" wide by 1/2" deep by 1/8" thick. I had to buy a 36" long piece and cut it to length; this was the biggest part of the material cost.
(1) 5/16" x 6" screw eye, with a center hole about 1" diameter.
(1) 5/16" washer
(1) 5/16" nut
(1) 1/4" x 1" hex head bolt
(1) 1/4" nut
(4) 1/4" washers

Tools I used (yours may vary):

10" miter saw with abrasive metal cutoff blade (to cut pipe and handle to length)
4" angle grinder with metal cutoff blade
Dremel with 1-1/2" metal cutoff blade
Hacksaw with tungsten carbide rod blade
6" bench grinder with grinding wheel and wire wheel
Flat bastard file
Drill with 3/8" bit
Hammer and centerpunch

The first piece is made from a 3/4" pipe, black iron or galvanized. Cut off a piece 3 1/2" long. You don't want threads on the bottom surface that contacts the valve spring retainer. Threads on the other end don't matter. Cut out the window in the side using an angle grinder with cut-off wheel, a Dremel, or a hacksaw if you're a masochist. I used an angle grinder for the straight cut about 1/4" from the bottom and the angle cut at the top of the window, and a Dremel with a little abrasive cut-off wheel to make the cuts parallel with the pipe. Grind or wire wheel all the cut edges smooth. I tried covering the bottom surface with electrical tape so it wouldn't scratch the retainers, but it doesn't stay in place very long. None of my new retainers got scratched anyway (they're titanium). The finished piece looks like the picture.
Attached Images
File Type: jpg pipe.jpg (56.7 KB, 418 views)

Last edited by OthercarisaFiat : 06-24-2004 at 12:37 PM. Reason: Additional info
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