Hydraulic clutch conversion.

Part the 4st,

This morning I lined up and bolted the oversized alu plate onto the 18mm MDF template.


This is what Im going to use in the router(its an old one)


I camped it all down to the bench and had at it.


rotating the whole thing while keeping everything lined up properly


and this is how it came out.


Im happy with the tap and die set that I bought the other week.


So,this is how it sits at the minute.


So far,so good.The aluminium is remarkably easiy to work with.Normal woodworking tools with lots of cooling WD40. Im thinking it looks a bit boring as is,so Im going to play around with the template and mark out some relief lines. See what more I can get away with using the router.
More later.

davido wrote:

OutsiderKZ900A4 wrote: Why a hydraulic clutch? I have had them and prefer cables for bikes, especially if I am going to be drag racing it.

I fitted the complete front end of a ZX9R to my bike,with the brake resevoir.So I wanted to fit the clutch resevoir for symmetry.( I like symmetry) Also,my original cable and lever control were shagged out and I didnt want to buy new ones .
I dont plan on drag racing and as kaw-a-holic says,its lower maintenence but mostly,I wanted to have a go. I saw some pictures of other bikes and thought it looked like a nice idea and not too difficult,so,why not.My whole build so far has been about learning new things,fiberglassing,welding ,powdercoating and working with aluminium.
Saying that,I am just having a go and if it dosnt work out,I can always switch back to the cable option.Nothing ventured,nothing gained.

Gotcha. I was just curious.

Thanks for this post Davido!

I'm curious to see how it works out so waiting to see your feedback.
May need to do something similar on the wife's 440 ltd

I've thought about doing something like that but using the stock cover. I use to have three but lost them to Meth Head scrappers. Maybe one day I'll try it.
Steve

There was a guy in Germany that was making conversion kits to use in the original cover.I dont have any details though. Sorry.

There is this option, but it doesn't come cheap and you still have to buy a slave cylinder japan.webike.net/products/1853627.html

Part the phith;

So,I decided to try and sex it up a little bit with some profile routing.What a drama!

On the 18mmMDF template,I marked out what I wanted.


I cut another template to shape. (With the copy bit Im using on the router,the template is 5mm over size to the final shape that I want)


Testing it on the 18mm MDF




Looks ok.Now for the real thing.



Not so beautiful.Sanding with the rotax didnt help much.Even the angle grinder didnt help


I ended up making ever decreasing templates to try and get a reasonably clean finish


This is the best I could do.



So,thats where it is at the moment. I plan to clean it up and drill some holes in it .Illl run it through the blast cabinate to even out the finish.

Nice work. Adds a little something to break up the lines. Where did you get the slave. link?
Steve

P.S.
I can see the attraction of using a CNC machine or even a table router would be better. I dont have a table router and though it would likley only take 5 minutes on a CNC machine,they have to program it which takes more time/money. I have the woodwork tools already and the aluminium plate cost,maybe 25euros so this was the cheapest way to go.
Here is my work table right now with all the templates I made for this project;



If your time is money,It might be better to just but one.There are plenty of aftermarket kits available,.Or draw out what you want and take it to an engineering company with a CNC machine.

swest wrote: Nice work. Adds a little something to break up the lines. Where did you get the slave. link?
Steve

Thanks Steve. The slave is from an early ZX9R

Yeah, but this one is all yours.
Steve

I have a friend with a flow jet....Quite a cool piece of equipment!
We draw parts in Inventor and export it to the flow jet. Not too expensive either!

Either way, good job on the cover dude!