zKars

Source for the Cup washers on the SU Air cleaner Wing Bolts

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    Part two.

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    Use die to drill 21/64 hole

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    Install on custom mandrel on the lathe and remove excess.

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    Parted off to right length. Quick sand paper polish while it’s spinning. 

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    Flash clean up on the inner edge of the parted cut complete. 

     

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    Final stage, a bit of dremel work to clean up any burrs and rough edges. 

    Scratches on the back side need to smoothed from contact area on the mandrel. Quick abrasive rub, then sandblast for consistent finish. Off to plating with the next batch of hardware. Hopefully not too far in the future....

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    Edited by zKars
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    Awesome. When you said you were going to cut off the excess material on the lathe, I was going to suggest trepanning. I suspected that if you tried a traditional outside edge cut, there was no way you were going to be able to do that mounted on a mandrel like that. The interrupted cut would have made that impossible. Either the part would spin on the mandrel or the corners would have just bent over. Seems you're a step ahead of me!

    Looks great!

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    14 minutes ago, psdenno said:

    Man-hours per piece?

    Counting his, mine, and granny's? About 40.   LOL  ROFL

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    2 hours ago, zKars said:

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    So? How about a close-up of one of yours next to a stock one??

    And just think... In the beginning, it was a pipe dream and all sounded so difficult!    :geek:

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    spacer.pngSee post # ... oh wait, no post numbers. Page one, 3/4 of the way down.

     

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    Edited by zKars
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    5 hours ago, Captain Obvious said:

    Counting his, mine, and granny's? About 40.   LOL  ROFL

    At a reasonable $100 an hour......only $4,000 per washer.  Any price break if I buy a pack of six?  😎

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    21 minutes ago, psdenno said:

    At a reasonable $100 an hour......only $4,000 per washer.  Any price break if I buy a pack of six?  😎

    Given the tough position so many of us are probably in or going to be in soon, you can have 6 for $4k. Canadian. 

    Good news is I’ll lots of time to make plenty. Got a big sheet of 18 gauge to gobble up.

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    On 4/2/2020 at 8:06 AM, Captain Obvious said:

    Agreed. Looks great!

    Next batch, get the hole centered.    :ph34r:   Back into my cave now.  Haha!

    Most are well centered. Not as simple as it seems. May have to build a jig to hold them steady and clamped in the press die so I can do it on on the drill press to ensure no creep. 

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    Got my plumbing washers in yesterday in the mail, got the centers drilled out to 5/16 and glued into the washers. 

    I think I have ~25 available now. I need about 12 to “Complete” the wing bolt sets I have, the rest are up for grabs.

     

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    Yes I cleanup the flash in the center.

    I drill them out to 5/16, but they are still a bit small, so I heat a slightly larger bolt and heat melt to enlarge and smooth out up the insides. They are a nice snug fit on the wing bolts.

    The washers are 11/16 OD with a 3/16 ID, so they have to drilled out. Can’t find 11/16 washers with a 5/16 hole.

    Next I’m working on serviceable and in-expensive total wing bolt and hex base replacements. They will be functionally identical but not perfect replica’s Won’t be able to tell with just the wing and washer showing when installed.

    Unless my wife says we need more masks....

     

    Edited by zKars
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    Sweet. Now you're the resident drawing expert. I love it when a plan comes together!

    So what's up with the wing bolts and hex bass thingies? You got a pic? You can chuck hex up in the lathe easily... Just sayin'. And I can probably teach you how to cut metric threads. Probably. Old dog.

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    If my plan comes together I won’t have to machine much of anything, let alone threads. I’m not aiming at a perfect or even a Really close forgery of the originals, just something that looks pretty close and functions properly, and that is cheap to create.

    My hardest machining task is to make a pointy ended bolt out of a regular one for the wing bolt, and cutting the head off of bolts to supply threaded stock. Raw parts costs will be in the $5 dollar range. I’m not even planning on getting the hardware plated, although that’s always an option. 

    I’ll keep the few sets of OEM hardware I have for the proper restorationists, the rest of us just want to keep our air cleaners on! 

     

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    You got collets for the lathe? You might be able to run the bolt through the collet (head inside the collet body and threaded end sticking out). If you can do that, you can set your compound on the lathe for the angle you want and cut your point easy-peasy.

    You can do the same thing with a regular chuck (instead of collets), but collets are easier on threads because of the wide gripping surface. Chuck jaws have a tendency to dent the threads. They work, but it's easy to mess up the threads. However, if you've got an unthreaded shank on the bolt, it may allow a land to tighten down a 3 or 4-jaw.

    I doubt I have pics of that kind of operation, but I'll take a look.

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    Raw materials are in

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    Young helper is learning to assemble bolts. 

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    24 minutes ago, zKars said:

    Raw materials are in

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    ...and a shot of bourbon to celebrate ?  😉

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    That is a candle holder, but now you’ve got my mouth watering for some proper Irish whiskey.    

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    Proof of concept.  

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    top is OEM, center is my forgery, bottom is the component parts that you start with. 

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    The wing nut is an M6 x 1.0 so I remove the hex head of a bolt, turn it down then run a die over it to thread. 

    Today I will experiment with ways to permanently affix the wing nut to the bolt. Red Locktite, welding, silver soldering  are all options.

    Sort of the same issue about the lower bolt that forms the threaded leg of hex coupler. It is threaded in 3 threads, then presently a thin nut is used to lock it in place. I would prefer to weld that in. I will likely TIG it on, then turn it smooth over the weld area. 

     

     

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    I initially bought M8 wing nuts, but they are quite a bit bigger than the M6 which are pretty much identical to the OEM wings (other than the silver zinc finish). 

    I can these as an option however, as they would be much easier to tighten and loosen than the stock size wing nuts. 

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    I must be spending too much time with my Grand daughter and the Disney+ movies. All I see is

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    Coolness.

    Since the only thing you're doing with the wing nut is locking it onto the stub of the bolt after you cut the head off, the threads there don't matter much. If I were doing that here, I would use imperial hardware. 5/16 (or 1/4 if I wanted a shoulder). I don't know if that makes your hardware choice any easier, but thought I would at least bring it up.

    So the original wing bolt looks like it was made from multiple pieces as well? I've never thought about it and don't even have anything that runs carbs right now. But it looks like they did the same thing you are doing with multiple parts. Silver soldered together maybe? Or just a tight press fit (which I think would work great for you too).

    Other input? You could chuck the hex coupler up in the lathe and taper the lead in hole for better target acquisition. It's not as big as the stock one, but you could provide some bevel there to help.

    I'm still thinking about the other end that threads into the carb faces... Wondering if red Loctite would be good enough there instead of the thin jamb nut. That red stuff is pretty tough. I wouldn't be surprised if the bolt would twist off before the Loctite let go (cold).

    You could cross drill, pin, and file flush. That would hide pretty well, especially if you're going to re-plate.

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    All good ideas. Sourcing the metric parts was easy, no need to bring any “outsiders” to the party.

    The original wing bolt is definitely two pieces, no sign of any brazing or soldering, maybe just a tight fit. 

    Red loctite might just do it. I’ll do one and see what kind of torque it can handle.I can’t use more than about three threads or I start taking up too much of the cavity for the wing bolt. 

    TIG’ing that bolt in there is the hot tip (haha) but I need to practice. Best thing I got was a face shield with a magnifying lens. Old people....

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