Differences

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--- techtalk:ref:tools147 [2019/05/10 00:14]
hippysmack [Pre-Ream Drill Hole Size Chart]
+++ techtalk:ref:tools147 [2024/01/24 21:50] (current)
hippysmack
@@ Line 5: / Line 5: @@
   * [[techtalk:ref:genmsr11|Cutting Oils, Soaking Oils and Lubes]]
-  * [[techtalk:ref:svcproc40#general_drilling_and_tapping|General Drilling and Tapping]]
+  * [[techtalk:ref:tools030#general_drilling_and_tapping|General Drilling and Tapping]]
+**Reaming**: \\
+Reaming is the process of cutting a larger hole to a specific diameter. ((oldmetal of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/30701-replacing-cam-cover?t=51086)) \\
+The purpose is to not only make the hole the correct diameter but also to align it and square it with the part that goes into it. \\
+This usually means aligning it with a hole, or bearing, opposite and at the other end of a shaft. \\
+Reason is because the cast part can not be manufactured to hold the required alignment tolerances (and in the case of aluminum, the required abrasion resistance). \\
+So, the cast part is made to accept a bushing made of a harder material that can endure the force and abrasion potential that goes with it. \\
+The bushing is then inserted into the casting but, because of the nature of casting, it is not in exactly the right place both in horizontal position and axis angle. \\
+So, the bushing is made with a smaller diameter hole than is required to allow for the precise alignment by reaming. \\
+**Line Reaming**:
+Line reaming is the process of using additional support features to help provide shaft alignment. \\
+In this case of reaming cam bushings, it is the cam cover and its associated bushing that is used to "line up" the reaming tool. \\
+The bushing hole in the right crankcase is cut to the correct size diameter, is properly located horizontally, and is cut square to the intended shaft axis. \\
 ====== Types of Reamers ======
+  *  Flute spirals. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3)) \\ All 3 reamers below are "right hand cut" meaning they all cut while being spun in the same direction as a drill bit. \\ Reamers come in different cuts as in straight, forward spiral, reverse spiral etc. Looking at the last one, you may think is cuts in reverse rotation but it does not.
+    * Straight reamers are by far the least expensive to buy. It also makes holes that aren't true cylinders. \\ They can have a lobed wall shape. This lobing goes hand in hand with amount of material being reamed away. \\ In our case it's a small amount of removal so the lobing is also very small. \\ For us it's ok for pinion & #2. But a spiral is nicer albeit usually 2X the cost. \\ It's also fine for 1-3-4 if bushes have no oil groove in bore. \\ Grooves in bore need the gap bridging action that spirals provide. \\ This is where you need spirals.
+    * Forward Spiral reamers will give a truer (but not perfect) cylinder. \\ Forwards gives the lowest cutting forces = easiest to hand ream with. \\ But they can 'grab' into the work (like a drill sometimes does).
+    * Reverse Spiral reamers are the best of the 3 for surface finish. \\ High cutting forces due to the reverse rake at the cutting edge makes the roundest holes of all three when driven by hand. \\ High safety in use. It won't toss you any curve balls but they dull quick. \\ All reamers when dull are useless.
-  * Reaming: ((oldmetal of the XLFORUM http://xlforum.net/forums/showthread.php?t=51086))
-    * The process of cutting a larger hole (to a precise measurement).
-    * The purpose is to not only make the hole the correct diameter but also to align it and square it with the part that goes into it.
-    * This usually means line reaming (aligning it with a hole, or bearing, opposite and at the other end of a shaft).
-  * Line Reaming: ((oldmetal of the XLFORUM http://xlforum.net/forums/showthread.php?t=51086))
-    * Line reaming is the process of using additional support features to help provide shaft alignment. In this case of reaming cam bushings, it is the cam cover and its associated bushing that is used to "line up" the reaming tool so that the bushing hole in the right crankcase is cut to the correct size diameter, is properly located horizontally, and is cut square to the intended shaft axis.
 L to R:
   - Jig bore reamer.
-  - Chucking reamer. (this reamer has a chamfered which is a good choice for blind holes and typically used in a machining chuck)
+  - Chucking reamer. \\ Chucking reamers are used in drill presses, turret lathes, screw machines, and other machine tools. They are also known as machine reamers. \\ It can be used by hand if you square the shank end with a grinder and you can use a socket wrench or tap wrench to turn it. \\ The shank is round or Morse taper and the cutting end of the reamer is ground with a 45° chamfer angle for easy hole entry. \\ (this reamer is a good choice for blind holes)
   - Bridge reamer. *this reamer has a lead in taper)
-  - Hand reamer (this reamer has a lead in taper just like the bridge type although the taper is much shallower)
+  - Hand reamer. \\ Hand reamers have a square portion at the end of the shank so the reamer can be turned by hand with an adjustable wrench or straight-handle tap wrench. \\ Most hand reamers have a slight taper at the cutting end for easy hole entry. \\ (this reamer has a lead in taper just like the bridge type although the taper is much more shallow)
   - Tapered reamer.
   - Shell reamer. (fits on an arbor)
-|1 thru 5 ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=3))|6. Shell Reamer ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=3))|
+|1 thru 5 ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3))|6. Shell Reamer ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3))|
 |{{:techtalk:ref:tools:reamers_1_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ref:tools:reamers_3_by_dr_dick.jpg?direct&300|}}|
+|A reamer cuts along its chamfer angle, \\ not on its outside diameter. ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3))|Bridge and Hand Reamers have a starting taper that \\ is too long for blind hole work. Each has a different \\ starting taper angle. ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3))|
-|A reamer cuts along its chamfer angle, \\ not on its outside diameter. ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904))|Bridge and Hand Reamers have a starting taper that \\ is too long for blind hole work. Each has a different \\ starting taper angle. ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=3))|
 |{{:techtalk:ref:tools:reamers_4_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ref:tools:reamers_2_by_dr_dick.jpg?direct&300|}}|
@@ Line 37: / Line 47: @@
 This reamer is specially designed for reaming the rocker arm bushings from 1957 to present. \\
-It is the right length and cut to fit into the old bushing on one end of the rocker arm and ream the new bushing in the other end.
+It is the right length and cut to fit into the old bushing on one end of the rocker arm and ream the new bushing in the other end. \\
+It has flutes which actually turn to the left but it is a "right hand cut" tool. \\
+Never turn it to the left while using it. \\
+|  "Jims" makes this reamer referenced to HD part number (94804-57). Use with a 12mm socket and wrench or a standard tap wrench. ((photos by Hippysmack))  |||
+|{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_32_by_hippysmack.jpg?direct&300|}}|
+===== Chucking Reamer =====
+You can use chucking reamers to ream bushings on a Sportster. \\
+But it is necessary to build or acquire a sleeve that slides over the shank portion of the reamer to keep center. \\
+And that sleeve OD is inserted into an opposite end of the piece you are working on to establish center. \\
+If it is necessary to control chip loss, an 8 flute chucking reamer will probably do better at holding chips than one with 4 flutes. \\
+\\
+This reamer sleeve was made for a 0.435" shank chucking reamer, by TPEHAK of the XLForum, from a 3D printer for use in reaming rocker arm bushings. ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings/page7?t=2072192&page=7)) \\
+You can see how it is used below. The centering sleeve is slid onto the reamer shank and the assembly goes into an existing bushing in the rocker arm. \\
+Then the reamer was chucked in a hand drill run at low speed to ream the new bushing on the other end. ((photos by TPEHAK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings/page11?t=2072192&page=11)) \\
+{{ :techtalk:ref:tools:cad_file_-_reamer_bushing_for_rocker_arm_by_tpehak.zip |Click Here to download the CAD file on the bushing}} \\
+{{:techtalk:ref:tools:replacing_rocker_arm_bushing_pic8_by_tpehak.png?direct&250|}}  {{:techtalk:ref:tools:replacing_rocker_arm_bushing_pic9_by_tpehak.jpg?direct&250|}} \\
+\\
+{{:techtalk:ref:tools:replacing_rocker_arm_bushing_pic11_by_tpehak.jpg?direct&300|}}
+{{:techtalk:ref:tools:replacing_rocker_arm_bushing_pic12_by_tpehak.jpg?direct&300|}}
+{{:techtalk:ref:tools:replacing_rocker_arm_bushing_pic13_by_tpehak.jpg?direct&300|}} \\
+\\
+These reamer sleeves were made on a lathe to use a spare cam cover and it's existing bushings to ream new inner cam bushings in the case. ((photos by Hippysmack of the XLFORUM)) \\
+{{techtalk:ref:tools:cam_bushing_installer_23_by_hippysmack.jpg?direct&300|}} {{techtalk:ref:tools:cam_bushing_installer_47_by_hippysmack.jpg?direct&300|}} \\
+{{techtalk:ref:tools:cam_bushing_installer_43_by_hippysmack.jpg?direct&300|}}
+{{techtalk:ref:tools:cam_bushing_installer_44_by_hippysmack.jpg?direct&300|}} {{techtalk:ref:tools:cam_bushing_installer_51_by_hippysmack.jpg?direct&300|}} \\
+===== Cam Bushing Reamers =====
+\\
+==== Outer Cam Bushings ====
+(AKA Cam Cover Bushings): \\
+The reamers for the cam cover bushings (#1, #3 and #4) need to be chamfered (chucking) reamers. \\
+The ends have a short chamfer that will enter the blind bushing bore and not hit the rear of the bore before finished cutting the bushings. \\
+The reamer for #2 cam can be a tapered bridge reamer on models with nosecone ignitions. \\
+(the hole for #2 cam is open  to atmosphere so the reamer has plenty of room to extend past the bushing) \\
+Else it will also need to have a chamfered end. \\
+Cam cover reamer sizes: \\
+-1990:
+/16" for the pinion shaft and idler bushing. \\
+-1/8" for #2 cam bushing. \\
+/16" for #1, #3 and #4 cam bushings. \\
+-up:
+/8" for the pinion shaft bushing. \\
+-1/8" for #2 cam bushing. \\
+/16" for #1, #3 and #4 cam bushings. \\
+==== Outer Cam Bushings ====
+(AKA Case Bushings): \\
+A single reamer is all that is needed for the case side bushings as all the cam bushings are the same size in the case. \\
+The normal way of reaming the case bushings is to split the case and ream case bushings by using the cover bushings as a guide. \\
+This will require a bridge reamer with a tapered end. \\
+If reaming the case bushings from the outside of the cover bushings, you'll need a chamfered (chucking) reamer with a short chamfer. \\
+The long taper will go in and touch the flywheel before the blades have a chance to cut into the reamer. \\
+So reaming the case side bushings will not be possible with a bridge reamer from the outside of the cover.
+Case bushing reamer size: \\
+/16" for #1 thru #4 cam bushings. \\
-|  "Jims" makes this reamer referenced to HD part number (94804-57) ((photos by Hippysmack))  ||
+|  Cam bushing reamers ((photo by decman of the XLFORUM https://www.xlforum.net/forum/general-area/off-topic-general-discussion/166860-this-week-in-my-shop/page6?postid=5016753#post3644788))  |
-|{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_2_by_hippysmack.jpg?direct&300|}}|
+|{{:techtalk:ref:tools:cam_bushing_reamers_by_decman.jpg?direct&300|}}|
 ===== Calculating Pre-Ream Drill Hole Sizes =====

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