Ohh I’m kind of exited Japanese 2 stroke??

Thepaetsguy

Well-Known Member

Buddys stick welder is an animal.. This is what we will call rough draft number 1 and I have absolutely zero trouble going all in 100% on the rough draft. the finish product will perfect.

I still don’t know if that plate is cast iron. IMG_6658.jpeg IMG_6659.jpeg IMG_6660.jpeg IMG_6662.jpeg
 
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Thepaetsguy

Well-Known Member

I’m trying my best to build in my head and machine holes without proper tools.


I need to order one 17mm bearing and one locking collar to have everything to finish the sidecover. This is a lot of work to add one single bearing to the output shaft so it supports a sprocket. WELL WORTH IT IMG_6662.jpeg IMG_6663.jpeg IMG_6664.jpeg IMG_6665.jpeg IMG_6666.jpeg IMG_6667.jpeg IMG_6669.jpeg IMG_6671.jpeg IMG_6672.jpeg IMG_6673.jpeg
 

Thepaetsguy

Well-Known Member

That copper bushing has three steps. I have the 1” locking collar on the second step the 1” collar is just not big enough to fit over the third biggest step.

I’ll take this whole bushing to tractor supply and before I buy anything will just grab a 1 1/4 locking collar off the clearance rack. If it fits the third bigger step I’m in business.

I need to take up the space between the 1” collar and the steel plate. IMG_6674.jpeg IMG_6675.jpeg
 

Thepaetsguy

Well-Known Member

Bolted the aluminum plate back to the steel plate and got a bit that just fit the ID of the copper bushing and drilled my hole for the output shaft.

With everything bolted together and the output shaft just sticking out of the case everything spins free as it should.

Now to buy one bearing and two locking collars to finish the job. You can see there is plenty of the output sticking out past the case for a bearing to support.

Edit: pulling the top shifter off and looking down through with all the internals assembled the gear lash is spot on! IMG_6676.jpeg
 

Thepaetsguy

Well-Known Member

I’m not a welder but I weld… A bigger locking collar is to thick and not gonna wrap around the bushing it’s just not the way.

No matter I welded bolts to the collar and welded the bolt heads to the plate. I’ll go back and clean it up with a grinder and paint the whole plate silver down the way…

One 17mm bearing with 35mm OD ordered and one locking collar with 35mm ID ordered. Easy work finishing this whole plate up. IMG_6678.jpeg IMG_6680.jpeg IMG_6681.jpeg
 

Thepaetsguy

Well-Known Member

I used a hand file. Edit: I know now what you mean and a chisel and big hammer to punch down through the remaining “pillars“ IT WAS A CAST IRON PLATE… I dropped it.

I’m not gonna be able to hand file steel as easy so add a rotory tool to the list…

Find a piece of real steel plate. Stick to the plan..

Just imagining myself in a factory in Japan in 1940 I just dropped the molds for the sidecase just run at that point.

IMG_6683.jpeg IMG_6684.jpeg
 
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Thepaetsguy

Well-Known Member

It’s all the same process as last time skip the small stuff. I need earmuffs a mask and a new pair of shop glasses before I pick up that grinder again.

My ears are ringing and it’s driving me insane.
 

Thepaetsguy

Well-Known Member

I agree, and I cheer him on !

And folks remember , @Thepaetsguy is in his twenties - wtf ?#%@& this kind of insight and fortitude usually takes many decades to develop , if ever !

Great work @Thepaetsguy you are inspiring !
My grandfather was 90 or 91 and could fix ANYTHING.. Same with my father and I grew up in the swamp with their tools and help.

They hated ANYTHING that was basically newer or unserviceable. So if something broke it was usually mechanical and with them around it was easily explained and often not really that hard to fix with no money. They had money they were just cheap and that was also very very good.

My uncle Glenn was in a wheelchair but basically ran the local montgomerys hardware and mechanical entirely by himself at points.
IMG_6690.jpeg IMG_6691.jpeg
 

Thepaetsguy

Well-Known Member

Steel is incredibly hard to work with.

I might just walk away for a few days after all this and try again. thankfully the local guy cut me out two tries. I’m already drilling holes wrong. IMG_6692.jpeg
 

Thepaetsguy

Well-Known Member

Maybe the holes are drilled wrong… Could be an illusion. I need to get the main gear hole for the bushing cut out and if it bolts to the case I’m still good.

If not well then I guess round 3
 

Thepaetsguy

Well-Known Member

We all get tired cranky and inevitably lazy…

I CANNOT BREAK the aluminum plate under ANY CIRCUMSTANCE. I do not even feel comfortable trying to tap out this bushing.

That means I cannot lay the aluminum plate flat against the steel plate and just clamp them together.

To make matters worse the bushing was not flat. I’ve taken a file and flattened the bushing surface to the best it’s getting.

Now to lay the aluminum plate on the steel plate with some spacers and do this right the third time. Don’t ask me how it worked so well the first time don’t know. IMG_6695.jpeg IMG_6693.jpeg
 
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