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Plastic B230F/B230FT Valve Cover Project - Input Wanted

B

blockgabe

New member
Joined
May 20, 2026
Sorry for the dupe from Swede Speed but I'm looking for input so visibility is needed.

3D printed for now. Plan on making them available one way or another, either for free as a file or for sale as a unit. SLS printed possibly in the future. Currently the full estimated weight once made out of Glass Fiber/Carbon Fiber reinforced Nylon is ~325g, stock valve cover is 859g. Removed the filler neck for additional weight savings and simplifying the print. Side benefit is hood clearance. Mostly a weight savings thing BUT the opportunity exists for additional features. Already took the opportunity to fix the rotation of the oil cap but there's definitely tons of different ideas for improvement. Also working on a plastic ITB intake manifold for weight savings and better thermal isolation. (Currently working part time so I don't have the money to work fast on any of this but I figured I'd throw out some lines to get opinions from the community.)

Materials cost:
~300g of PPA-GF or CF plus support material is ~$20 per valve cover. If you don't have a printer, services will print the current rough design for $200-$300 delivered. That cost shouldn't change as the design evolves.
+~$8 for M6 standoffs
Optional:
+~$8 for M6 Threaded inserts for coil packs

Current feature ideas:
  • Threaded mounting holes for LS coil packs.
  • Threaded mounting holes for VW wasted spark coils.
  • Valve cover mounted PCV box, valve, vent pipe, or AN threads.
  • DONE Volvo 1332494 Valve cover style reinforcement ribs (Lubrication improvement? Valve Cover venting improvement by separating oil sling?)
  • Changed clearances for RTV gasketmaker instead of a paper gasket.
  • Groove for rubber O-Ring Gasket
  • Ability to easily change the file to relocate the oil cap for different applications
  • Built in spark plug wire holders
Design Additions:
  • Standoffs for bolt holes to prevent creep
  • Threaded inserts for coil packs
Format:
If you guys wanted this, what format would you want it in?
Orderable pre-printed part (Probably ~$150)
.blend file (I hate CAD software, its too different from what I've learned)
.stl Files of each configuration

Suggestions for features on the ITB manifold are also invited.

This is the Volvo 1332494 valve cover with the reinforcement ribs btw
Silver


These are the current (Pretty worthless as of right now) PETG test pieces as I nail down the dimensions and overall design.


Silver Steel Nickel Carbon fibers Titanium
Image

Cylinder Steel Titanium Nickel Fastener
Carbon fibers
 
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nice idea. an idea i’ve had is to use a GM V8 style filler cap thread because there are a lot of options for those. much more compact, o-ring seal, plastic/aluminum options, and vented/pcv fitting options.
 
RvolvoR said:
You should just put and area for a baffle near the rear with a -12AN orb port on it.
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esmth said:
nice idea. an idea i’ve had is to use a GM V8 style filler cap thread because there are a lot of options for those. much more compact, o-ring seal, plastic/aluminum options, and vented/pcv fitting options.
Click to expand...
Both of these are good ideas
 
esmth said:
nice idea. an idea i’ve had is to use a GM V8 style filler cap thread because there are a lot of options for those. much more compact, o-ring seal, plastic/aluminum options, and vented/pcv fitting options.
Click to expand...
1779385250469.png
this type?
 
So, oil drip is hard to explain. But picture you bracing in the valve cover that would be placed above valve springs or at least the exhuase v. spring. So the bracing web would come to a point right above the valve spring so it would run down the webbing and drip onto the spring, which helped cool or keep it from over heating.

One thing is though we have a cam in the way, lol but could still drip onto the cam lobe. Years ago, when I was helping a circle track guy he bought a set of valve covers that had webbing like I just explained. I dont know if there is a need for that or not. Im sure ralley racers would like it. Ill see if I can find a pic or what Im talking about. But a baffle in the v.c. would diffently make me a buyer.
 
esmth said:
nice idea. an idea i’ve had is to use a GM V8 style filler cap thread because there are a lot of options for those. much more compact, o-ring seal, plastic/aluminum options, and vented/pcv fitting options.
Click to expand...
GM caps are common in the US, but not in the rest of the world. Perhaps something more universal, but still with lots of options? Nissan or Honda maybe?

Having a location for a PCV would seem to be a good idea. Since most PCVs mount in a boss in a cast head, they are difficult to arrange inline with a hose. Something like a Nissan SR20DET valve is common and seems appropriate for the size and type of engine (2L Turbo).
 
90volvo said:
So, oil drip is hard to explain. But picture you bracing in the valve cover that would be placed above valve springs or at least the exhuase v. spring. So the bracing web would come to a point right above the valve spring so it would run down the webbing and drip onto the spring, which helped cool or keep it from over heating.

One thing is though we have a cam in the way, lol but could still drip onto the cam lobe. Years ago, when I was helping a circle track guy he bought a set of valve covers that had webbing like I just explained. I dont know if there is a need for that or not. Im sure ralley racers would like it. Ill see if I can find a pic or what Im talking about. But a baffle in the v.c. would diffently make me a buyer.
Click to expand...
Hi

How do you make the oil drip past the pusher cup and up onto the spring inside ?
 
thats why I commented on we have a cam in the way. But when I say valve spring, Im including the spring and the assembly. If the spring is hot Im sure the shim and keepers etc. are hot and oil would help cool them. Im sure some ralleye guys on here would know if heat was problem on long races, which Im sure it is. Just google search there is plenty and read about it. HAve a good day.
 
Models for Optional LS coil mounts and optional PCV baffle. No testing has been done on the PCV baffles so no guarantee that they stay that way, just working out a concept for where they could possibly fit. Very little space and I still want to save weight so I don't want a bulbous baffle box on top.
LS Mounts EARLY.PNGPCV EARLY.PNG
 
90volvo said:
thats why I commented on we have a cam in the way. But when I say valve spring, Im including the spring and the assembly. If the spring is hot Im sure the shim and keepers etc. are hot and oil would help cool them. Im sure some ralleye guys on here would know if heat was problem on long races, which Im sure it is. Just google search there is plenty and read about it. HAve a good day.
Click to expand...
you have more than just a cam in the way....have you ever even looked inside of a b230 8v head? It doesn't sound like it.
 
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