I just used unvarnished/ glued cork floor tiles , from memory they were 5mm thick, make a template big enough so that the insert is slightly oversize, then squeeze them home so you get as near as possible equal amounts of cork each side of the plate. To true everything up glue a sheet of coarse sand paper to a dead flat surface ie a piece of glass and rub each side of the plate on this. The bike, a B31, has just done its third race and the plates look as good as the day I redid them
Gidday pooch, you cut the inserts so they're a little oversized so you have to compress them slightly to get them in... trial and error here to get the template the right size. I hope I don't confuse the issue here, but I will attempt to describe the fitting proceedure that worked for me...the cut-outs in the plates are tapered, fit the insert in to the narrow/inner edge of the cut-out first, then compress the cork with your fingers as you fit it into the broarder/outer edge of the cut-out. If your template is too big the resulting corks will be difficult to fit and will actually get a hump in in one side and a hollow in the other. Boiling the corks will soften them but I found the cork I was using was ok without doing this. In my post I said the clutch had done 3 races...should have said 3 race meetings,so heaps of laps. I was a bit daunted when I decided to try and do the job myself but was plesantly surprised at how easy it was and the satisfaction I got from using this ancient method. Check your plates are perfectly flat before you start, 'coz there's no way you'll build a nice clutch if they're nice and true.
Hi Pooch, yeah a punch would be the way to make a heap of inserts real quick, making the punch being the hard part. Cork cuts well with any sharpe blade though.
Tracking down floor tiles that weren't varnished or glued took a bit of effort as well...to be honest, the first inserts I made were cut from old place mats, the type you put your dinner plate on so Mums oak table dosn't get scarred...let us know how you get on, Bazza.