Norris Crown Corv-8

With the engine tuned for best power, it was now time to advance to the next stages of the rebuild; interior engine cover construction, fabrication of the new (rear located) trunk floor and supporting structure, body work and paint. The engine cover would come first.

During his shakedown cruises to test the all systems, Rick ran the mid-engine Monza without an engine cover. This enabled him to closely monitor the new engine during the break-in period and gave him a good idea of what qualities he should build into the cover, other than the obvious fire protection. He decided to built the unit in two pieces; an sheet aluminum firewall, and a plywood top cover lined with aluminum. Details of their construction are seen in the photos that follow.

Cruising in warm weather without the engine cover, Rick discovered that the water cooled mid-engine drove interior temperatures into the unbearable range, particularly when the side were windows closed. Insulation from both sound and heat would be a must.

The Firewall

At right, a front view of the engine cover firewall piece to be located between the seats and the engine. Sheet aluminum is pop riveted to a welded frame. Rick wanted a little design to his cover, instead of squared off ends. He used a Workmate bench as a bending brake, along with 2 x 4 stock, angle iron, hand tools and a rubber mallet to bend and form the sheet metal.

Corv-8 firewall

During the years Rick spent visiting Corvair events and examining how others had isolated their Crown conversion V-8s from the cockpit area, he put this design together in his head. He chose a lightweight combination of 1" square aluminum tube, 1" x 1/4" flat bar, and 1" x 1" x 1/16th angle stock to form the frame. Combined with other materials, as we'll see, he succeeded in providing the necessary fire protection and insulation from heat and noise.

Corv-8 firewall frame detail

Dynamat sound absorbing material was bonded to the aluminum with spray adhesive. Later, after this picture was taken, heat insulating material was added. It will appear in subsequent photographs.

Automotive seam sealer was used where aluminum panels were joined, effectively safeguarding cockpit occupants from engine vapors or fumes.

Corv-8 firewall sound insulation and seal sealer

The Engine Cover

Viewed from the passenger side, we see both pieces of the engine cover during a test fitting. Later, the pieces were painted and covered with automotive carpet. The underside of the plywood cover piece is fitted with aluminum sheet for fire protection and a layer of heat insulation. Rick used 1" x 1/8" adhesive backed weather strip at all sealing surfaces. The lid slides into an aluminum U channel at the back and is held down by custom thumb screws (not present in this photo) at the front. Engine cover removal is quick and easy.

Fit up of firewall and engine cover