Make Your Own Elephant Ears

Page 4 - Finished Product

Page 1 Patterns Part 1
Page 2 Patterns Part 2
Page 3 Alternator Mount

The last step of the process is to attach the frame brackets. I drilled a 3/4" hole in the center of each bracket for a plug weld. This adds a little strength as theres simply more welded area to hold. They should also be welded all the way around the edge. Dont skimp, and if you're a bad welder, get a friend to do it. You dont want your engine coming out :) Clean the surrounding area thoroughly with a paintable solvent, prime and spray your favorite color...you did save some paint from the last paint job didnt you???
The final result. 
 

 

 

Pulley alignment worked out perfect using this deep water pump pulley and a 2-groove crank pulley from a smallblock I had under the bench. One bolt hole doesnt line up in the smallblock pulley. I just ovaled it with a drill and all is fine. If your alignment isnt perfect, you may be able to just use shims behind the pump pulley.  The shims are available in Summit and Jegs for about $4, and include 2 1/16 shims and a 1/8. The common method is to just mill the water pump the thickness of the ears plus gaskets. I thought, why bother paying for milling if the alt will be in a new location anyway? At least for me, it worked out better this way too.

One other step in this project is optional. A torque limiter. It's 3/4 or 5/8 tubing with a rod end and bracket. It bolts to the engine mount boss on the block and runs forward or backward diagonally towards the frame, where it bolts on to a welded bracket. Higher powered cars may see the engine flexing fore/aft under acceleration or braking. You can make one, or they're $40 from most chassis shops. If I decide to make one, you know you'll see it here :)

 
My poor old faded engine block looks like crap now. From start to finish, I spent an honest 2 days working on this project, plus time for the paint to dry. Now I have even MORE room for monster headers:) Once again, I can say, theres no better feeling than doing it yourself..... Now get wrenchin'

Page 1 Patterns Part 1
Page 2 Patterns Part 2
Page 3 Alternator Mount