Dave Wellings Coil Pack Protector

Dave Wellings Coil Pack Protector

Apparently there have been cases with the 4 cylinder Zetec, where water has come in through the louvres and caused a misfire.

Although the Roadster coil pack is high up at the front of the engine bay, any water which gets in can run down the HT leads and may cause a misfire.

So for a while I've been wondering if a coil pack cover is feasible. thinking

In the end I turned to Origami......

 

Next I turned to the scrap box where I'd salvaged some aluminium from an old shower.

Out came the snips, and hey presto.........

Then came the tough part - the folding.

I must be getting better, because one attempt produced this:

The centre fold will locate between the two rows of HT lead caps.

Next, after some shaping with a hammer, and a trial fit:

Next the lining.

4mm standard density neoprene over the centre fold to locate the shield, and 3mm on the horizontal sections.

There is a slight overlap all the way round.

No chance of an HT short with this insulated lining.

Another trial fit..........

More to follow>>>>>

Next I applied the outer cover, using high density neoprene,which keeps the shape better..... using aerosol adhesive.

This overlaps the aluminium former by quite a margin as you'll see next.

Underneath - where the 'overlaps' will be subject to engine heat I've applied Reflect-a-Cool adhesive heat barrier, and you should know by now where I get this stuff.

It's looking quite good........

A final trial fit:

It's a push fit, and holds in place very well, but next a road test is needed to make sure it stays put, and doesn't get too hot.

2017 Note: This is still in place and doing the job.