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  1. #1
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    Mercury 2.4 litre mod-vp cowl conversion

    So I had a crazy idea and I'm going for It. I'm attempting to turn a 1995 mercury 175 black max Cowl into an 86-93 2.4 litre mod-vp cowl. At first I thought that all I had to do was make a bottom pan, A few body mods and boom, Showtime!!! I purchased a Cowl on eBay for a good price and after observing it much closer and comparing it to pictures from Google images, i'm starting to think the black max Cowl is a little fatter. But I really want to be sure before I chop it.
    So if anyone out there who has a 2.4 L mod VP can take a few measurements for me I'd really appreciate it. I just need the width front and back from the top corners.

  2. #2
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    Click image for larger version. 

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  3. #3
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    Okay, so this thread is really boring right now but I will post updates and pictures as it moves along. The black max Cowl looks eerily similar to the Bridgeport cowl bClick image for larger version. 

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ID:	340162ut a little wider. I will figure out the exact width before I cut and narrow it . So far I've managed to rig a plate to engine for the bottom pan, where there were three vent holes on the top now have five. In the middle of it there are two raise portions that I need to grind down and flatten out. After that I can cut the front vent wing in. I'm trying to make this as close to the real thing as possible but It will have a few subtle differences. Hoping to have this wrapped up by June, but my time is limited it may take longer.
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  4. #4
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    Next i had to flatten the raised portion in the middle. I used an angle grinder to take it down then block sanded it to make it all flat. I will have to skim coat with glazing putty and block sand it again to fill in the few low spots.Click image for larger version. 

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  5. #5
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    ... And then I had to build up the 2 inch section towards the front where the vent wing will be cut out. Just used standard fiberglass with polyester resin and blended in with and blended in with light weight filler.
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  6. #6
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    Do you still need measurements? I can take some tonight when I get home. Which ones?

    Seems like a lot of work to keep from buying a $300 cowl/pan.
    Keith-

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  8. #7
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    Yes thank you Keith. I just need the top two measurements on the front and back corners similar to the ones shown on my first post. If I had it my way I would have bought one by now but they are hard to find and I don't always have $300 ready to go. I have had this idea rolling in my head for a few years now and at this point I am determined to finish just to see if I can do it. These are the kind of projects I love to do. Those two measurements would be gold to me that way I can at least get the dimensions right so it doesn't look out of proportion. The rest the measurements I have been able to scale with a photo.

  9. #8
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    I'll get those for you tonight.
    Keith-

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  11. #9
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    Here they are. Same order as your pics...
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    Keith-

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  13. #10
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    Keith, I can't thank you enough. That is perfect.So the black max cowl i'm working with is about 16 inches at the rear and about 11 1/2 at the front. And from what I can see your Bridgeport cowl is 14 3/4 of an inch at the rear and 10 inches on the front. So I'm looking at 1 1/4" to 1 1/2" difference. In my head I was thinking it was closer to just 1 inch but I'm not too far off. I'll probably just split the difference and cut 1 3/8". Project moving forward...

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  15. #11
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    ...ok so i've cut the vent wings out. Was planning on leaving the front attached and then bending it in but that piece had too much of a curve to it, so I ended up just cutting the whole thing out in anyway. Click image for larger version. 

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ID:	340835So filling in the entire two and section toward the rear was a waste of time. I could have just filled the upper and lower corners just a little.
    So after cutting them out I made pieces for the inside section by molding it from the inside of the cowl ( still curved but not so dramatic will look more precise).Click image for larger version. 

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ID:	340839 for the outside edge and center piece i'll just use balsa wood.
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  16. #12
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    Shaping the vent wings have been a tedious process. Trying to get all the lines to roll smoothly. This part is the signature detail so it must look right. I finally got one side done and now I get to do it all over again on the other side. Click image for larger version. 

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  17. #13
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    I don't know how many different versions of that cowl there were, but mine doesn't look quite like that... what you're calling the "wings" I guess, are divided down the middle.
    Last edited by David - WI; 04-15-2016 at 11:44 AM.

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  19. #14
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    Yes, I will add that later. It makes it easier to shape the outer walls with that removed. I guess the names i use for the details are a little misleading, i call it a "vent wing" even though they aren't functioning vents but they sort of resemble a wing.

  20. #15
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    Technically, I think it was modeled after a NACA duct, but there is no hole, so it's just for aesthetics.
    Keith-

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