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Buell Forum » Old School Buell » Archive through January 10, 2015 » Info on cutting down the cam cover? « Previous Next »

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S1owner
Posted on Thursday, November 20, 2014 - 10:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Here's the deal I have done a lot of research and just wanted to see if I could get some others thoughts.
I cut mine down no problem but on certain years there is a milled hole in the bottom plugged with a brass plug. This hole was there for lubrication during the milling process. So how to plug the hole again?
Some say a machine screw and red lock tight? Can I buy a new plug? Should I reuse the old plug? What have others done?
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Mtjm2
Posted on Saturday, November 22, 2014 - 03:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

what's the best way to cut the cover down while still on the bike ? Toying with the idea and like some of the pics I've seen with it done . If you've done them S1owner , help a brother out !
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S1owner
Posted on Saturday, November 22, 2014 - 03:25 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I did mine on the bike took about 45 min. Here is the process I used and the tools.
Tools: 4 1/2" grinder with a thin cutting wheel, wax pen for drawing on the cover, flexible ruler to conform to shape, various metal files.
Process: measure underneath to make sure of your measurements, use the grease pen to mark and draw your pattern. With a super steady delicate hand use the grinder to cut it up use files to smooth it out. Sand polish to desired finish. If you have the brass plug like mine you will need to plug it again like I am asking about above
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S1owner
Posted on Saturday, November 22, 2014 - 03:27 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)


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Pash
Posted on Sunday, November 23, 2014 - 04:29 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I drilled and tapped mine 1/4 UNC then loctited in an allen (cap) screw to plug it.
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S1owner
Posted on Sunday, November 23, 2014 - 08:49 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks Pash
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Mtjm2
Posted on Sunday, November 23, 2014 - 11:12 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks S1owner ! Think im going to do it !
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S1owner
Posted on Sunday, November 23, 2014 - 11:28 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

No problem just remember measure 3 times cut 1. Take your time let the tool do the work.
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S1owner
Posted on Sunday, November 23, 2014 - 11:29 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Also if you have the hole in the bottom like my pic shows drain your fluid first!!
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