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| techtalk:ih:engmech01a [2018/05/16 21:19] – [Sprocket Cover Dowel Hole (Case) Repair] hippysmack | techtalk:ih:engmech01a [2023/12/31 19:34] (current) – hippysmack | ||
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| ====== IH: Engine Mechanicals - Sub-01A ====== | ====== IH: Engine Mechanicals - Sub-01A ====== | ||
| ====== Sprocket Cover Dowel Hole (Case) Repair | ====== Sprocket Cover Dowel Hole (Case) Repair | ||
| - | Article by Hopper of the XLFORUM ((http:// | + | Article by Hopper of the XLFORUM ((https://www.xlforum.net/ |
| - | * 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 | + | * 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 |
| * 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 | + | * 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 |
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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 | + | | Drill jig made from a half-inch steel plate to guide the drill ((photos by Hopper of the XLFORUM |
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| * Because the top hole has a 1/4 bolt running through it, and the weld was off centre, I made a special drill/ | * Because the top hole has a 1/4 bolt running through it, and the weld was off centre, I made a special drill/ | ||
| - | | {{: | + | | {{: |
| - | | Using an electric drill (and proceeding very carefully), came up looking like this. ((photos by Hopper of the XLFORUM | + | * 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. |
| + | * I also drilled and tapped that top stud out to 5/16 for more strength and also plan to add a steel angle bracket from the top of the sprocket cover to the two bolts on the top of the gearbox near rear mounts. SOB will not move ever again!! | ||
| + | * I still had to strip the gearbox and replace those bearings that had been welded right next to. | ||
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| + | | Using an electric drill (and proceeding very carefully), came up looking like this. ((photos by Hopper of the XLFORUM | ||
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