I decided to try my hand at making a custom fuel rail cover for my car. I has a custom made CF fuel rail cover in place for the last couple of years but decided its time for a change. The old CF cover has become warped, cracked, faded, etc and is only going to be used for template purposes. I started with a 12" x 24" piece of 26 gauge steel sheet.

I began by cutting out a section about 4 1/2" x 15 1/2" and then bent over about an inch from the end. I then measured the locations of the holes. I will admit that I probably should've went off the brackets on the car. My holes are about 1/4" off so I will be modifying them into slots to compensate for the difference.

As for mounting I am going to be coming up with my own mounting system. The person that sold me the custom CF cover came up with a way that worked but I dont much care for it. I will be tapping out the bracket holes that once contained the engine cover riser bolts. Given the size of the holes that were left from grinding out the risers I think I will be taping them out with a M7 x 1.0 tap. To mount the cover I think I will use the simplest of means. I plan to get a M7 x 1.0 bolt that is about 40mm long and use it with about a 1" nylon spacer. I will then place the spacer between the bracket and the cover. From there I will put the bolt threw the cover & spacer and screw it into the bracket. I may also use a small washer between the bolt and the cover.

Here are some preliminary pics so far. Hope to try and get the mounting hardware later today to see if my plan will work.







UPDATE:
Just got back from running some errands and test fitted my mounting hardware setup. Looks like I was wrong about M7 x 1.0 bolts working. Once I tapped the bracket with the treads there wasn't enough for the bolts to grab onto. I'll have to go up to M8 x 1.25 tap and bolts instead.

The spacers also need to be adjusted a little as well. The left side may need something a little smaller and the right side something a little bigger. Not 100% sure yet as I was unable to get the cover mounted securely. Once I get the new bolts and install the cover securely; I will be able to make a better judgement as to what may or may not be needed.

For now here are a couple of test fitment pics. Enjoy

NO COVER


FRONT VIEW WITH COVER


SIDE VIEW WITH COVER

 

Looks good! I would be down to buy your CF one if you're willing to sell. It would flow with my CF hood! Let me know by PM if you want to get rid of it!

 

Mines held up 5 years. How was your last one made?

 

The last one someone else made by fibercation out of Ohio. Someone sent him a steel template and they reproduced a couple in CF. From what I know it sounds like it was a fiberglass base with CF added over top of it and then resin added over that. The piece has been on the car since around 07 so I got my fair share out of it. Where it was bolted down there are stress cracks and the entire piece is a little warped on the lef side. The right side bolt area has been ripped open more due to the way it was mounted. It did not want to come off and I practically had to tear it off the bolt and then deal with removing the bolt later.

I loved the piece and it was the only one around. The other one that went to the person who created the original template also broke. One of his friends leaned on it a little too much and it snapped. He since started to use his steel template instead