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techtalk:ih:engmech01a [2023/12/19 22:40] hippysmack [Sprocket Cover Dowel Hole (Case) Repair] |
techtalk:ih:engmech01a [2023/12/31 19:34] hippysmack |
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====== Sprocket Cover Dowel Hole (Case) Repair ====== | ====== Sprocket Cover Dowel Hole (Case) Repair ====== | ||
Article by Hopper of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools?t=395586)) | Article by Hopper of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools?t=395586)) | ||
- | * This is a bit of an obscure one but a real pain to fix, requiring several special tools. This was also done with the cases assembled. If had split the cases I could have put them on my mate's milling machine and precision machined them. But because I was too lazy to split the cases and disturb that nice tight, factory original bottom end, I did it the hard way. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586)) | + | * This is a bit of an obscure one but a real pain to fix, requiring several special tools. This was also done with the cases assembled. If had split the cases I could have put them on my mate's milling machine and precision machined them. But because I was too lazy to split the cases and disturb that nice tight, factory original bottom end, I did it the hard way. ((Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/172350-77-breather-please-view-pics/page2?t=1845601&page=2)) |
* When it came back from the aircraft welder it looked like the pics below. | * When it came back from the aircraft welder it looked like the pics below. | ||
* Amazingly, there was no big blob of weld but two tiny little rings, still with the (rough) hole in the middle. His TIG welder can weld aluminum .010" thick. | * Amazingly, there was no big blob of weld but two tiny little rings, still with the (rough) hole in the middle. His TIG welder can weld aluminum .010" thick. | ||
* The gearbox shafts and bearings were left in place during welding to help stop distortion of the cases. | * The gearbox shafts and bearings were left in place during welding to help stop distortion of the cases. | ||
* He pre-heated the cases gently with a torch and then he would put a ring of weld on, let it cool off, repeat, repeat repeat etc. | * He pre-heated the cases gently with a torch and then he would put a ring of weld on, let it cool off, repeat, repeat repeat etc. | ||
- | * Notice how he welded around the screw next to the top hole but did not go over it. And the 1/4" threaded hole in the middle was still useable. ((photos by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586)) | + | * Notice how he welded around the screw next to the top hole but did not go over it. And the 1/4" threaded hole in the middle was still useable. ((photos by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/172350-77-breather-please-view-pics/page2?t=1845601&page=2)) |
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* I also sleeved the sprocket cover down with a steel sleeve so the hole for the footpeg stud was a tight fit and would take most of the weight in future. | * I also sleeved the sprocket cover down with a steel sleeve so the hole for the footpeg stud was a tight fit and would take most of the weight in future. | ||
- | | Drill jig made from a half-inch steel plate to guide the drill ((photos by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586)) || | + | | Drill jig made from a half-inch steel plate to guide the drill ((photos by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/172350-77-breather-please-view-pics/page2?t=1845601&page=2)) || |
|{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_3_by_hopper.jpg?direct&400|}}|{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_4_by_hopper.jpg?direct&400|}}| | |{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_3_by_hopper.jpg?direct&400|}}|{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_4_by_hopper.jpg?direct&400|}}| | ||
* Because the top hole has a 1/4 bolt running through it, and the weld was off centre, I made a special drill/cutter out of 7/16" silver steel. It had a 1/4 inch hole up the centre so it could fit over a threaded stud screwed in the hole. I cut two flutes on the end of it with an angle grinder so it is like a milling cutter, or flat-nosed drill. Finished it off on the pedestal grinder. I then flame hardened it with the oxy torch. Heated it cherry red then quenched in oil. Then tempered it to a light straw color and quenched again. | * Because the top hole has a 1/4 bolt running through it, and the weld was off centre, I made a special drill/cutter out of 7/16" silver steel. It had a 1/4 inch hole up the centre so it could fit over a threaded stud screwed in the hole. I cut two flutes on the end of it with an angle grinder so it is like a milling cutter, or flat-nosed drill. Finished it off on the pedestal grinder. I then flame hardened it with the oxy torch. Heated it cherry red then quenched in oil. Then tempered it to a light straw color and quenched again. | ||
- | | {{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_5_by_hopper.jpg?direct&400|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586)) | | + | | {{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_5_by_hopper.jpg?direct&400|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/172350-77-breather-please-view-pics/page2?t=1845601&page=2)) | |
* In the final fit up, I made custom dowel pins and fitted them with a small file and some bearing blue so they are tight as tight and wont work loose again. | * In the final fit up, I made custom dowel pins and fitted them with a small file and some bearing blue so they are tight as tight and wont work loose again. | ||
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* I still had to strip the gearbox and replace those bearings that had been welded right next to. | * I still had to strip the gearbox and replace those bearings that had been welded right next to. | ||
- | | Using an electric drill (and proceeding very carefully), came up looking like this. ((photos by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586)) || | + | | Using an electric drill (and proceeding very carefully), came up looking like this. ((photos by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/172350-77-breather-please-view-pics/page2?t=1845601&page=2)) || |
|{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_6_by_hopper.jpg?direct&400|}}|{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_7_by_hopper.jpg?direct&400|}}| | |{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_6_by_hopper.jpg?direct&400|}}|{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_7_by_hopper.jpg?direct&400|}}| | ||
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