I started by test fitting the cone and using modeling clay on the case. I used a aluminum bit in my dyegrinder to fit it as close as I could. I was also on a tight timeline to get it done so I could have spent more time and used less filler but oh well it's done.
Once it was close I filled the nosecone with marine tex and taped it in place to set up the next day I welded it on in 5 spots about 3/4 inces each. A picture would be nice but like I said.... The welds were at the top just above the bullet and one on the bottom by the skeg. I then used more marine tex to fill in any gaps and make a smooth transition from the nosecone to the case.
That was the easy part now at this point you need to drill a large hole and tap it under the waterpump. I spent about 3 hours trying to measure everything so it would come out right. The hole hase to be perfect if it's too far back it will hit the wall for the exhaust cavity, too far forword it will hit the upper bearing for the driveshaft, and too high it will hit the water pump base plate.
As you can see I was just a bit too high but I got lucky and the base plate still seals.
You will need to grind on the front edge of the cavitation plate for the fitting.
At this time I used polyester with some cabosil to fill the old pickups, I just taped them off and filled it from the top.
I then taped the hole and connected the hose.
I then sanded it smooth and plan on waiting till winter to have it finished up and painted. It works gerat and took about 7 hours to do.
Looks more time consuming than anything.
