Timing Cover Mod for Adjustable P7100 Pump Gear

[Turbo1967]

Cross posted on the other Cummins Forum as well.

Hey Guys,
I am in process of modifying the front timing cover of my 96 12 Valve to provide access to my adjustable P7100 Pump Gear. I realize aftermarket aluminum covers are available, and I took a good look at them. But I want to see if I can pull this off myself and be satisfied with the results. I purchased a DCEC chinese cover as I didn't want to cut up my factory cover. I was a little disappointed that it didn't have the doubler plate tacked inside, but for $54 shipped to my door...oh well. Over the past couple of years I have purchased a few DCEC items through DB Sales on both the Jungle Site and Flea-Bay. I have been completely satisfied up to this point.

I will be using an aftermarket gear case as a welding fixture to help keep the adapter straight / reduce the chance of the heat warping the cover.

I have attached pictures of my progress so far. I will drill the holes for the fasteners after the adapter is welded to the cover.

 

[bateman]

Looks factory. I like this over the shiny billet offerings.

 

[Turbo1967]

Looks factory. I like this over the shiny billet offerings.

Thanks! I recessed the 1/4" plate halfway into the cover, about the same amount of the thickness of the original doubler. All in an attempt to have the oil fill tube come as close as possible to bolting back up. I expect to have to elongate the bolt hole in it.

 

[kawi600]

I just got a timing gear from crazy carl's and didnt want to do a billet cover so will be watching this..
I was gonna just cobble something, but its the round cuts that are the problem. maybe something like the tool they use in HVAC to cut plenum for round joints.

 

[Turbo1967]

So this modification to my timing cover could have been done with simple tools like a reciprocating saw or plasma cutter. I choose for me the "hard way" to force myself to learn how to use some old equipment (rotary table) that I purchased some 25 years ago and never used. I am a hobby machinist / fabricator, and any opportunity to learn a new skill is always fun. Following are pictures of the progress.

 

[Turbo1967]

Here are the remaining pictures.