Workshop Sunday Oct 6

jbcollier · Post by **jbcollier** » Tue Oct 01, 2013 7:54 pm

There will be a club workshop Sunday Oct 6. We will meet at 9 a.m. at Sports Car Centre (12116 - 121a St, google-map it as it is a bit tricky to find the first time). We will be having a good look at David's BMW engine and probably stripping it to get the case welded.

david · Post by **david** » Sun Oct 06, 2013 7:48 pm

Great to see everyone that came out today. And, thank you so much. With out your help, John and I would of had to do something very creative to get the work done.

Andrew · Post by **Andrew** » Sun Oct 06, 2013 8:28 pm

Very glad to hear the engine came apart just as it looked it might one we had it on the bench. Thanks to watching John's masterful technique, I am now a bit less afraid of the idea of dismantling a motorcycle. It inspired me to go home and fix the window switches in my son's car and to repair and reset the garage door opener --

jbcollier · Post by **jbcollier** » Sun Oct 06, 2013 10:05 pm

I've never seen so many plastic zip ties in my life. I think I cut off almost twenty. I must confess I was a little relieved when the bottom/gearbox section came off so easily. I mean, it makes sense it should do so but they're mostly designed for ease of assembly these days, not ease of repair. Here's hoping it goes together as easily as well. Please someone make sure I line up all the dowel pins correctly

Now we just have to strip out the shift drums and the selector mech and it's off to the welders.

jbcollier · Post by **jbcollier** » Wed Oct 09, 2013 11:19 am

Ugh:

http://s250.photobucket.com/user/jbcoll ... 6.jpg.html

jbcollier · Post by **jbcollier** » Wed Oct 09, 2013 11:22 am

De-ugh-ifacation started:

http://s250.photobucket.com/user/jbcoll ... 8.jpg.html

Machined up a new spigot and dropped it, along with the case, off at the machinist this morning. When they're done milling the broken area flat, I'll machine the spigot to the proper length and then off to the welder.

jbcollier · Post by **jbcollier** » Fri Oct 18, 2013 4:33 pm

Here is the case after machining:

http://s250.photobucket.com/user/jbcoll ... sort=1&o=0

Here it is with the spigot machined to length and placed in position:

http://s250.photobucket.com/user/jbcoll ... sort=1&o=1

Off to the welder Monday afternoon.

Andrew · Post by **Andrew** » Sun Oct 20, 2013 6:27 pm

It looks slick, and looks like it'll stick--

jbcollier · Post by **jbcollier** » Mon Oct 21, 2013 4:17 pm

Dropped it off at the welders today. The foreman looked doubtful but the welder phoned later on in the afternoon to ask a few questions and figured he would be able to do it. Should know for sure in a couple of days.

jbcollier · Post by **jbcollier** » Tue Oct 22, 2013 1:21 pm

The welder phoned me this morning practically crying because the weld had not turned out to their satisfaction. I girded my loins, amongst other things, and headed down, fearing the worst. Thankfully it was just a case of the poor pampered bast#rd never having welded slightly contaminated materials before. When you weld contaminated materials, the contaminants form gasses that make it difficult to make a perfect weld.

It looks just fine:

http://s250.photobucket.com/user/jbcoll ... sort=1&o=2

I'll smooth things out and vacuum check it just to be sure.

redbike · Post by **redbike** » Wed Oct 23, 2013 12:48 am

The mind swoons at the prospect of anything which might contaminate a bit of German engineering...wars have started over less.

Andrew · Post by **Andrew** » Thu Oct 24, 2013 5:53 pm

Yeee-haw! Looks like it succeeded! Fingers crossed for the pressure test--

jbcollier · Post by **jbcollier** » Mon Oct 28, 2013 5:38 pm

Well, it worked in that the spigot was firmly welded to the case, but the case alloy was chosen for its castability rather than its weld-ability. I carefully ground out a groove in the two passages and then filled them both with two part alloy epoxy. I did the first and let it sit over the weekend. That worked a treat so I did the second this afternoon. I'll test it tomorrow and then let it sit another day before polishing it all up with a dremel.

Finger's crossed but it looks to be good.

jbcollier · Post by **jbcollier** » Thu Nov 07, 2013 6:42 am

Sealed and tested one passage no problem now I just have to do the other. Sorry for the long delays but it's busy at work and at home. Now I have to use a dremel and smooth things out and test again.

Andrew · Post by **Andrew** » Thu Nov 07, 2013 8:32 am

Great news on yet another non-riding winter day, John -- OK, ANYTHING motorcycle related is great news in winter. But it's good to think of Dave's bike back on the road in spring!