Machining project part 1: New Oil plugs

[SpeedyManiac]

Hi guys,
I'm taking a machining class right now (Intro to Manual Machining) and thought I'd share my first project. As many of you probably know,the GasGas drain and fill plugs leave a lot to be desired. Namely, the allen wrench interface and soft aluminum material. I used aluminum for the new plugs, but put a 12mm hex head on them so they are much easier to remove and install. The plugs were made from 1" diameter 6061-T6 aluminum, turned down on a lathe. The hex head was cut on a manual milling machine.

Here's the finished product:

 

[JTT]

Nice job Speedy! Now you just need to press in a magnet for the drain plug

 

[SpeedyManiac]

That's the plan once I source a magnet.

 

[gasgasman]

Nice!
Hope you get an "A" on your project.

 

[MattR]

Nice job Speedy!

Just be careful with the 12mm wrench when tightening. You may snug it up more without realizing it and strip threads. If you make another version sometime, you may want to consider 8mm or 10mm hex heads.

 

[SpeedyManiac]

Thanks for the thoughts, Matt. I considered a smaller head, but figured I'll just use my head when tightening it.

 

[GMP]

Nice job.

If you make a plug for the trans fill, cut a groove for an o-ring so it is captured. I use an o-ring on the stock plug but you have to be carefull not to overtighten and force it out of position. Works good when carefull.

Make some front wheel spacers from stainless. I do this as well as rears and never change bearings from grooved spacers letting water in.

 

[SpeedyManiac]

Thanks for the suggestions GMP. Right now I'm working on some bar mounts (similar to the universal fastway clamps) but if I have time I'm going to make wheel spacers. My only issue with wheel spacers is if I make them out of stainless, I'll need to heat treat them to get the surface hardness up to something respectable. Am I correct in thinking that regular stainless (not sure whether I should be using 304 or 316) won't be tough enough to withstand the abrasive environment?

 

[JTT]

Am I correct in thinking that regular stainless (not sure whether I should be using 304 or 316) won't be tough enough to withstand the abrasive environment?

They'll be tougher than the stock alloy ones you can be sure

 

[GMP]

Joe is right, they will be fine and last a few seasons, WAY longer than anodized aluminum. Even Les's prototype stainless rear spacers were not heat treated and the one I got in '03 is still in the bike. My brother and I do this all the time on every bike, as there is a small machine shop in town that welcomes walk in business.

Correct me if I'm wrong but I think 304 is harder but less corrosion resistant than 316 right? Mine are made from 316, not a spot on them.