A few days ago I posted this photo of a styrene test piece for the covers on the engine:
My plan was to make a rubber mold and cast these things in resin. But that test piece was too rough. Well, I tried a couple more and couldn't get it to look as good as I wanted. So I tried a different approach, making it out of 1mm Sintra and scribing the indentations. That turned out even worse:
Even if I could have created a suitable master, I had doubts about how well such thin pieces would reproduce as castings. So I scrapped the whole idea and decided to come up with a non-prototypical design that would be simple enough that I could make all 20 of them individually. My first test of this was extremely simple, just a flat piece of styrene with rounded corners and a nut/washer in the middle:
But I felt that this was TOO simple. I wanted something that looked a bit more interesting. The design I settled on was made by layering two pieces of .020" styrene. Both pieces had the corners rounded, and I beveled the edges of the smaller piece before gluing it on top of the base piece. Here's how they turned out:
I also did some work on the base for the engine and generator:
Having operated more Diesel / Natural gas engine's then I can count on both hands, the covers you made up are more then
suitable for a engine you are working on. Certain once in place no one will notice.
I put my Diesel project on hold to finish? up a few other project's. It is a Fairbanks-Morse 3 cly version of the F-B shown on the site you posted.