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Thinking outside the box #772378 04/30/19 7:02 pm
Joined: Feb 2007
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edunham Offline OP
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Just had an experience that for me was thinking outside the box, and was ultimately quite satisfying. I was working on one of my little Italian bikes. The rocker arms pivot on special bolts. The bolts go in through a hole on one side of the rockerbox which is part of the head casting. That hole starts off at 14mm and tapers to 12mm. On the other side the pivot bolt is anchored in a blind 10 mm hole. The threads in the 10mm hole were stripped. In order to get any kind of insert in the 10mm hole, I have to work through the tapered hole.
I calculated that a Heli-Coil should fit and ordered a 10mm x 1.5 kit. When I got it, I checked and everything fit, although barely. Next problem was that there wasn't going to be room for drills or tap handles because the frame was in the way. At first I was resigned to pulling the engine, but then I thought about it a little more and paid a machinist buddy to make up a drill bit extension and a tap extension that would fit into a collet type tap wrench. Just as importantly, he made up some small guides to fit into the top of the 14mm hole to keep everything in line.
The gurus on the website forum for the bike all predicted disaster and that I would not be able to keep everything straight enough. My thought was that if I followed their advice I would have to pull the engine, remove the head and send it to a specialist. Well if I botched the job, that's what I would have to do so I might as well give it a try. I did it last night.
No power tools, just the tap wrench, careful measurement and grease. Working nice and slow, it took 45 minutes including cleanup. Worked like a charm. No binding and the pivot was nice and straight.
It was very satisfying to post on the Italian forum this morning. The point however, is that if I hadn't thought about extensions, I would have had to pull the motor, and if I had listened to the gurus I would have pulled the head and waited 8 weeks for the work to be done.

Ed from NJ

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Re: Thinking outside the box [Re: edunham] #772388 04/30/19 8:42 pm
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Lannis Offline
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Originally Posted by edunham
..... a machinist buddy .....

Ed from NJ


This is SUCH a rare and valuable thing! clap

The only thing better is to actually BE the machinist buddy ....

Lannis


Play stupid games ... Win stupid prizes!
Re: Thinking outside the box [Re: edunham] #772392 04/30/19 9:35 pm
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edunham Offline OP
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I should mention, he is more of a enthusiastic home machinist than somebody at a professional shop. And I do pay him, although it is usually a lot less than what I would pay a shop. Payment is usually along the lines of "How much do I owe you?" Well it took me a lot longer than it should of, so how much do you think is fair?" How about X?" "Fine." In this case I paid him $100 for 4 hours of work to make the extensions and the guides. He was happy with that and so was I.

Ed from NJ

Re: Thinking outside the box [Re: edunham] #772435 05/01/19 11:07 am
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Al Eckstadt Online Content
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Good thinkin' Ed. I have a friend like that nearby. He has a home shop with a (very) large lathe, milling machine and welders. He's helped me think through problems many times as well as doing actual machine work and welding.


Al Eckstadt
Re: Thinking outside the box [Re: edunham] #773269 05/10/19 7:44 pm
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wadeschields Offline
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Thats using your noggin Ed ... Glad it all worked out thumbsup

Last edited by wadeschields; 05/10/19 7:44 pm.

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