CCT replacement/ alternator bungs

[Murv]

Mine turned up today
It's surprising (and probably a bit sad) how excited I can get over a couple of lumps of metal, but these are beautiful

[tony.mon]

Mine turned up today
It's surprising (and probably a bit sad) how excited I can get over a couple of lumps of metal, but these are beautiful

Agreed.

Almost too good to waste on a thirteen-year old rattly hack like mine........

[TonyW650]

Mine turned up today.
Very nice, well impressed
cheers

[Xenocide]

These are beautiful. One question though...

How the hell do you make the allen headed holes? Always wondered that.

[gl_s_r]

I broach them with a hexagon headed tool....

[Xenocide]

I don't know what that means but it sounds bloody impressive.

[Xenocide]

Woahhhhhhhhhhh

[gl_s_r]

bit antiquated that one...

This is more like it. http://www.youtube.com/watch?v=tg0q2kgIVxo

[lloydie]

you made us a work of art

[VTRDark]

bit antiquated that one...

This is more like it. http://www.youtube.com/watch?v=tg0q2kgIVxo

I can't get my head round that one. If it's spinning it then cuts at the highest point of the bit, so makes a circle.

How do you fancy having a go at making some caps for the swingarm where it meats the frame?

(:-})

[gl_s_r]

It revolves at the same speed of the material you are broaching.

The broach has a small angular offset to it at around 1 or 2 degrees so it actually pointing off centre. Then when it hits the part it synchronises speed wise and in effect is actually stationary. The angular offset I mentioned earlier then moves in a rotary fashion and it effectively forms the hexagon by gently beating the material, it doesn't really cut a shape but rather shears it by "pecking" the shape.

You'll see the chamfer at the front of the hex and the hole being deeper than the hex I put in is a necessity to broaching.

I have read that back and it does sound more complicated that what it is... I'll see if I can find another link to make it more "sensical"?

In this link http://www.youtube.com/watch?v=BhvNU2E_x_Y you can see the broach stop on contact and then wobble to form the hex in the plastic..

[gl_s_r]

Did you mean some caps to replace the plastic ones in the footpegs?

[seb421]

Did you mean some caps to replace the plastic ones in the footpegs?

that would look nice!

[VTRDark]

bloody hell, that broaching is clever, I think it makes sense to me now. So the wobble effect is like having a cam so you get the high point and low point as it spins. That's my lesson learned for today.

Did you mean some caps to replace the plastic ones in the footpegs?

Exactly the biggest problem with the plastic ones are that they wear on the edges from a screwdriver being used to pry them off when using an Abba stand, and they are just tacky looking.

(:-})

[Xenocide]

I just wanted to say thank you very much to gl_s_r, my bungs turned up today and they're a work of art! I'm in love. Phoawrrrr