The last few years I have been machining sections from Aluminium to suit my V6. Thought I would post some of the photos.
 
Rocker covers first side.
 

 
The second operation I machined a jig to the shape of the inner profile to locate the previously machined inside and also drilled and tapped the holes. Initially used hex bolts to hold the cover down and then in turn with the program machined each of the holes with a counter bore hole and install cap heads. I then machined the outer profile. Used a 12 mm long solid carbide cutter to get the depth. The carbide cutter has far less flex compared to the HSS cutter.
 

 
 

Finished machine and deburr. Still to machine breather holes and then send for black anodize.
Finish thickness on top and sides is 4 mm.
 

 

 

Number plate frames to suit MK3, the front mount backing plate is different to the rear plate.  Bezel bolts on with 4 mm S/S cap screws and holds 2 mm clear poly-carbonate sheet and the number plate in place. To be black anodized as well.
 

Coming up next, front timing cover, alternator and cooling.
 

Nice work...
 
Looks like it would have been a big chunk of Alu to start with!
 
Shaun

I can really appreciate the hours you've put in for such beautiful machining, as I did 4 years in the machine shop when I did my apprenticeship in Toolmaking/Marine Engineering back in the 70's............wish I had the machines and the time to emulate your efforts for my own GTV6.
Well done ! 

Jamman,
 
A professionally machined rocker cover.  More of your metal working skills that never fail to amaze.  What next?  How about a 4 litre, 4 bolt main alloy V6 block.
 
Regards
John 

Alloy block coming next John!
 

Front timing cover with fittings added for injection and ignition sensor. 85 amp alternator with bracket on right side.
Vernier timing gear cover machined at a later date.

 
 

Split fittings with oring sealing into welsh plug holes and small bleed holes to pickup the highest point in heads. Orings seal between the fittings and to heads.