DIY billet clutch cover

[steliost]

The clutch cover on the EC250 started weeping from where it was already welded and I put some Mannol cold steel epoxy there but it did not convince me enough... On the search for a new cover I found out they are pretty scarce and expensive.

So I decided I would try to make one out of a fat slice of aluminum on the lathe and mill. Fun! A bit less than 25 euros of material and 3-4 hours of work, with breaks, and here we are. I had to cut off the excess material around the flange with a handheld grinder since my milling machine is quite old and does not support such intricate cuts, and that was the most time consuming and boring part of the operation. Not much fun. aluminum dust all over the place.

I left 1mm more room on the inside for the clutch and went about double the thickness on the face for extra durability, the stock is only 4 mm and caves in like that! I know it's a bit rough around the edges and heavier but ehh... saved us a 100 euros at least and the hassle of searching all around the interwebs.

 

[Neil E.]

Nicely done! It sure is great to have access to machine tools.

 

[steliost]

Sure is, bud! cheers

 

[(F5)]

That's cool. Now here's my gift to you. I also have a blue anodized yz kick lever.

Gell oven cleaner. Wipe on, brush, wipe off. Repeat twice. Perfect.

 

[Anders]

Nice work! I have have had similar thoughts, but ended up with buying Rekluse covers.

 

[steliost]

Thank you gentlemen! F5 nice tip, will do it next time i'll have it off the bike. Anders that was our first thought also but they were mostly out of stock and around 150 euros. Not that the bike is not worth it but since i had the means to do it and had the OK from the actual owner i tried it and it seems like a good choice so far. And that satisfaction of doing something useful with your own hands is the cherry on top!

 

[Anders]

And that satisfaction of doing something useful with your own hands is the cherry on top!

Indeed! I have a lathe (old Harrison) and a small mill. I make some motorcycle parts myself, as well as tools for maintaining the bikes.

I also do some wood work. Right now, my main project is refurbishing an old workshop (inherited from my dad and uncle). It is approx 100m2, with garage / workshop at ground level and a woodworking shop at the first floor. It stood with a leaky roof for years, now I have to replace parts of the wooden constructions due to lots of rotten wood. I did the roof some years ago, now it's the rest. Will take me a couple of years, I think.

 

[steliost]

I also got the tools and the shop passed on to me from my father when he retired, as he had from his father. I am a machinist by trade like both of them, grew up in the shop practically and I enjoy working in that environment! I've got two lathes, a mill, a 50 ton press, a couple of column drills, two welding machines (MIG and stick) and a bunch of hand tools, taps etc. Mill, lathes and the big drill are Czechoslovakian and Polish made, very sturdy. they used to work non-stop back in the day...
Success in your endeavor, mate!

 

[Neil E.]

Years ago machinists who knew the value of sturdy machines always bought Czech machine tools. We have them at work and they are still going strong after at least 40 years.

 

[steliost]

Yes, so true. every old machine shop, at least around here has a czech piece of machinery still working with great precision. they have returned their value in money many times.

 

[farmerj]

Yes, so true. every old machine shop, at least around here has a czech piece of machinery still working with great precision. they have returned their value in money many times.

I'm going off topic here, but has anyone ever ridden one of the old CZ motocross bikes? I remember seeing them in Dirt Bike magazine when I was growing up ("back in the day"!).

Jeff

 

[Neil E.]

I haven't ridden a CZ motocross bike. My buddy in high school had one. It was a twin port model with two exhaust pipes. CZ machines would win if the rider was strong enough to force the machine around the track. When long travel suspension became the thing to have, many small manufacturers just didn't have the resources to keep up. MAICO did well with their long travel setup. Penton/KTM and Husky were able to get by.

I bought a brand new ISDT JAWA 350. Interesting bike with a right side forward kickstarter. One piece engine casting; the crank assembly came out the left side. The gearbox cluster came out the right side. Top gear was a transit gear that was way high. Had to be almost wound out in 4th to get into 5th.

 

[(F5)]

My Sheldon lathe is belt drive probably 50s. Wouldn't be without it even if it is pretty rubbish. Matches my skill with it.

 

[swazi_matt]

like this one?

(that is about a 60+ tooth rear sprocket!!)

 

[swazi_matt]

not sure why it isn't posting the pics

https://share.icloud.com/photos/0WEWOt2Tso2bBQAtIeMvitpbQ

https://share.icloud.com/photos/0DqPxWz_F7PYYsQMW0lVn7jew

 

[Neil E.]

Like this.

 

[siNN]

On the search for a new cover I found out they are pretty scarce and expensive.

With the scarcity you might be on to something there, Have you thought about selling a few?

 

[steliost]

Have you thought about selling a few?

Yes, that crossed my mind but I suppose I could do that at a local level meaning inside greece or the balkans maybe. the cost of the cover itself would be close to that of a recluse one though, it takes time and effort and I got a shop to maintain! I could post that in a greek dirtbike forum and see if anybody's interested...