another perfectly good motorcycle ruined.......

Wednesday, 26 January 2011

 next step on the front pulley cover was to mark it out for some slots milled across the face, i found the centre of the new sprocket and scribed a circle the same size on the outside of the casting, bit of a fiddle to set it up square on the miller bed as the cover is convex so i had to pack it up with a couple of bit's of aluminium stock, dangerous made short work of milling the slots but i had not given the cast webbing on the inside of the cover a thought, [top photo], i dropped the cover on the bike and it looked odd where we could see the webbing behind the milled slots, only one thing to do, reverse the cover and mill out the webbing, easier said than done and with hindsight it would have been easier to do this first, [bottom photo], then mill out the slots, we had to use a very small end mill which leaves a lot of hand finishing to do but i reckon it will look pretty trick when it's done.

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