After discussion with Ken, I have taken on this project.
Here are my findings:

Clear Engine Cover
OK, had a long meeting today with the guy from the plastic forming company, took my car to bits to suss out what where why and when and have come up with the following.
We can make a “smooth” copy of the existing cover (nice rounded corners and without the strengthening ribs). If we make in 4 or 5mm thick Lexan Polycarbonate material the existing carpet/foam cover will still fit over the top for normal use, and we use the standard Gasket to seal it to the body.
Therefore we then come to a few options and pricing.
Pre Production Items
1. Buy original Aluminium Cover
2. Work to make it smooth and hi-gloss finish with extra lip for moulding
3. Make female GRP mould, from Item2
4. Make Specialist Male Resin mould from Item 3
Total for Pre Production work = $3500

This is including all hand finishing work on the original pattern, intermediate mould and final resin mould.
This is of course a one off cost Final selling price would then be dependant on how many people come on board

We would then have 3 options
1.Vac form Final Product from 4-5mm Lexan Polycarbonate this would be good to replace existing aluminium cover and run with the carpet over the top, when not in “show “ mode. Cost this option $570 each plus Preproduction Costs as above

1A. If option 1, we could then offer a further enhancement if required: Hard coat Lexan, to stop scratching. Extra cost for this option $270/item

2. and / or make final product from Vac-forming Acrylic this would be a SHOW only option.
Cost this option $430 each plus Preproduction Costs as above.

Then all covers would be hand finished and polished and would have a Black Etched outer edge ( a little like your rear screen) to finish the job off.
BTW The Plastics guy makes all the race screens (side and rear) for Aston Martin as well as the rear screens and side screens for all Porsche GB cars… so quite obviously he knows what he’s doing.

So:
Option ONE (THIS WILL BE THE PRICE YOU PAY)
Cover Made in 4-5mm Lexan Polycarbonate
If 10: Cost each $900
If 20: Cost each $750
If 25: Cost each $700
If 50: Cost each $630
If required an additional process can be undertaken on the above option which puts an Extra hard coating on both sides of the material This would add $270 to each of the above prices (This can be a one off and therefore doesn’t affect the quantity prices)

Option TWO
Cover Made in 4-5mm Acrylic (This would be for show ONLY)
If 10: Cost each $775
If 20: Cost each $600
If 25: Cost each $560
If 50: Cost each $500

Note: Whichever option you choose, doesn’t matter for the total
Just as a by the way, All costings have been rounded UP. So this is the maximum price, it may well be lower when final production starts!

Now I’m quite prepared to help in the project, and give my time free. (chasing and Product Managing) But I don’t really want to invest $5-10 000 in it. (well not for No profit) So to move this we first of all need numbers. Then we, at some point will need commitment. There has obviously been quite a lot of interest over the past months or so:-
It’s now in your hands. DO WE CONTINUE ???
If your still interested, please add your name,or start a list below. Just so we can get an idea of serious numbers.
We will leave it, lets say, one week from today. Then consider our options !!
If we are going ahead with this I would like to think within 3-4 weeks we will see something and delivery wouldn't take that long after.

I will start the list

1. K-Man S - prefer option 1A
2.
3.
4.
5.
...

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K-Man S
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I'll pay the extra and have it "hard"........Oh,...yes please madam ...My wife says it must be an age thing??????

Originally Posted by K-Man S
I will start the list

1. K-Man S - prefer option 1
2. Tess Tickle Option 1A
3. Spydr OPTION 1
4.
5.
...

Im going to join, but first I was hoping you could provide some clarification and perhaps entertain a crazy idea of mine that I think others would like.

Question: Would the extra hard coating in option 1a reduce noise and heat at all, and make it better to drive around without the foam\carpet cover on, then doing this without having the extra hard coating.

Ideally, I prefer always having the engine show, even in day to day driving.

Crazy idea: Have you considered in addition to making the vacuum fit piece to replace the aluminum heat shield, also a flat piece to replace the carpet piece. This would allow the cargo surface to be maintained while providing a cooler and more silent alternative for those who wish to drive day to day with the engine showing.

In an ideal world, I think the vacuum fit cover to replace the aluminum could be made with regular lexan polycarbonate and the flat cover to replace the carpeted piece could be made with extra hard coating, as it would serve as a more practical cargo service when the need arises.

- Suneet

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- Suneet


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Suneet your idea’s are not crazy, and Yes I think there is a possibility of adding this top cover at a later date. My biggest concern is trying to keep the price to something that I consider "reasonable". And another Mould is not where I want to go at the moment.
The reason that I thought of the hard coating was to stop scratching, not from debris from the pavement but when the cover is cleaned and polished...by the owner.
The biggest "unacceptable” noise that you get when you take the carpet off is the sucking noise made from the air filter area when you open the throttle. Again the idea is that when you want to, You put the carpeted cover on to reduce the noise. So it gives you the best of both worlds.

Joe Twelve Pack - Option 1A

Originally Posted by K-Man S
I will start the list

1. K-Man S - prefer option 1
2. Tess Tickle Option 1A
3. Spydr OPTION 1
4. Joe Twelve Pack - Option 1A
5.
6.
7.
8.
9.

I would take OPTION 1A (with the scratch-resistant coating). As my daily business involves polycorbonate, I can tell you EMPHATICALLY the poly scratches VERY easily w/o a SR coating.

Separately, I would like this cover to be made with the appropriate underside "bulge" that would more reasily permit the installation of the various aftermarket plenums (X-51, softronic, etc.).

Is this possible?

my thoughts

Barry

Well, I have been a strong supporter of the clear engine cover since day 1; so I will take option 1. The flat cover should be very easy to cut and produce, since it's flat, so I will pursue that venture on my own if I feel like more sound or heat proofing is necessary.

I will start the list

1. K-Man S - prefer option 1
2. Tess Tickle Option 1A
3. Spydr OPTION 1
4. Joe Twelve Pack - Option 1A
5. Suneet - Option 1a
6.
7.
8.
9.

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- Suneet


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Barry as we have not started yet, tell me a little more, as we might as well get as many alternatives in the design to start with.
We are starting with the standard aluminium cover with the intention to “smooth out” all the ribbing and make the whole thing as smooth as possible. So what and where do you need the modification ?

Originally Posted by K-Man S
I will start the list

1. K-Man S - prefer option 1
2. Tess Tickle Option 1A
3. Spydr OPTION 1
4. Joe Twelve Pack - Option 1A
5. Suneet - Option 1a
6. besantini - Option 1A
7.
8.
9.