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--- techtalk:ref:engmech01m [2018/10/29 17:17]
hippysmack [To Protect the Aluminum from Scratches While Cutting]
+++ techtalk:ref:engmech01m [2019/05/28 03:00]
hippysmack removed
@@ Line 7: / Line 7: @@
   * [[techtalk:ref:engmech01o#pics_of_sprocket_cover_mods|Pics of Sprocket Cover Mods]]
   * [[techtalk:ref:engmech01l#ignition_cover_mods_and_aftermarket_covers|Ignition Cover Mods and Aftermarket Covers]]
+  * [[techtalk:ref:svcproc45#refshop_notes_and_tips|Polishing Aluminum]]
 ====== Some Suggestions and Tools ======
+You can get it professionally chopped on a milling machine for around $100. (polishing not included) \\
+|{{:techtalk:ref:engmech:cam_cover_mod_1_by_aswracing.jpg?direct&300|}}|{{:techtalk:ref:engmech:cam_cover_mod_2_by_aswracing.jpg?direct&300|}}|
+|  Custom cam cover professionally cut down ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1728113))  ||
 **Benefits of chopping the cover**: \\
 There no benefits whatsoever of chopping the cover other than to change the cosmetic appearance of it. ((Moved On http://xlforum.net/forums/showthread.php?t=22500V)) \\
@@ Line 75: / Line 81: @@
     * A mechanical or CNC mill is very helpful for precise and non-jagged cuts.
-|Cutting area marked out with tape. \\ Cuts made with an angle grinder with the metal cut-off blade. ((photos by Johnny Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=467551))||
+  * **Caution**:
-|{{:techtalk:ref:engmech:cam_cover_mod_1_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:ref:engmech:cam_cover_mod_2_by_johnny_wolf.jpg?direct&300|}}|
+    * Be in control of any power cutting tools at all times. Kick-back can do serious bodily harm. \\ If the cover jumps out the clamped area, let it fall. Make sure the cutting blade has stopped and the tool properly secured before worrying about the cover.
+    * Learn the safety rules for the tool before using it.
+    * That is __not__ meant as a cliché. An angle grinder can get loose and tear the skin to the bone before you know it.
+    * If you're not accustomed to using the tool, practice first on some scrap material before cutting your piece.
+|Cover cut out with a hacksaw. ((photos by daggar rider of the XLFORUM http://xlforum.net/forums/showthread.php?p=2046656#post2046656))|Cutting area marked out with tape. \\ Cuts made with an angle grinder with the metal cut-off blade. ((photos by Johnny Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=467551))||
+|{{:techtalk:ref:engmech:chopping_cam_cover_with_a_hacksaw_1_by_daggar_rider.jpg?direct&300|}}|{{:techtalk:ref:engmech:cam_cover_mod_1_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:ref:engmech:cam_cover_mod_2_by_johnny_wolf.jpg?direct&300|}}|
 |Cover mounted to 2x4 table end with large "C" clamps and cut with a saws-all. ((photos by EvIL sTevE of the XLFORUM http://xlforum.net/forums/showthread.php?t=1395634&page=2))|||
@@ Line 86: / Line 101: @@
 ===== To Protect the Aluminum from Scratches While Cutting =====
-    * Painters tape.
+  * Painters tape, placed on the cut line can help keep down rips and jagged edges at the cut line. \\ It will also help keep the tool from marring the finish that you want to keep. \\ You can also use it to tape off areas to keep out debris.
-    * Soft jaws in a bench vise.
+  * Soft jaws in a bench vise (soft plastic or rubber) may help will marring of the finish. \\ However, soft jaws may not allow you to get the piece tight enough in the vise. You may have to play it by ear.
-    * A towel to wrap the cover in before chucking into a bench vise.
+  * A towel to wrap the cover in before chucking into a bench vise or as a soft base for your work piece.
-    * Plywood between the cover and the vise or clamp jaws.
+  * A small piece of cardboard can also serve as a soft base for your work piece.
+  * Plywood can be used between the cover and the vise or clamp jaws for surface protection.
-|Place the tape over all areas where the cutting tool might \\ butt into the cover. The towel protects the cover from \\ being gouged by the vise jaws. ((photo by Johnny Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=467551))|
+Place the tape over all areas where the cutting tool might butt into the cover. \\
-|{{:techtalk:ref:engmech:cam_cover_mod_1_by_johnny_wolf.jpg?direct&300|}}|
+The towel protects the cover from being gouged by the vise jaws and can serve as a soft base for hand work. \\
+{{:techtalk:ref:engmech:cam_cover_mod_1_by_johnny_wolf.jpg?direct&300|}} ((photo by Johnny Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=467551)) {{:techtalk:ref:engmech:chopping_cam_cover_with_a_hacksaw_2_by_daggar_rider.jpg?direct&300|}} ((photo by daggar rider of the XLFORUM http://xlforum.net/forums/showthread.php?p=2046656#post2046656))
 ===== For Holding the Cover While Cutting =====
-    * Bench vice.
+  * The bench vice above will work well for cutting the cover with a handsaw.
-    * Wooden table while clamping the cover to it large "C" clamps.
+  * The wooden table below while clamping the cover to it with large "C" clamps will hold the cover tighter in place.
+  * However when using an angle grinder or most power saws, if the blade catches the wrong way while cutting, it will jerk the piece out of the work station (or the tool into you).
+|Cover mounted to 2x4 table end with large "C" clamps and cut with a saws-all. ((photos by EvIL sTevE of the XLFORUM http://xlforum.net/forums/showthread.php?t=1395634&page=2))|||
+|{{:techtalk:ref:engmech:chopping_cam_cover_with_a_saws-all_1_by_evil_steve.jpg?direct&300|}}|{{:techtalk:ref:engmech:chopping_cam_cover_with_a_saws-all_2_by_evil_steve.jpg?direct&300|}}|{{:techtalk:ref:engmech:chopping_cam_cover_with_a_saws-all_2.1_by_evil_steve.jpg?direct&300|}}|
 ===== For Shaping and Smoothing =====

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