Machine Shop Idea: Oil Pump Cover

[Steve_in_Florida]

(This is partially to test the polling function offered by the site)

Background:
In past lives, I've been a computer programmer and systems administrator. I'm currently working in a friend's small machine shop, surrounded by several manual and CNC lathes and mills.

The CNC devices can be programmed to make parts that are designed with computer software.

I'm new to this aspect, and want to learn more. Hands-on is the approach I like to take.

We have a bunch of aluminum scrap pieces that would be ideal for practice. The part that immediately jumps to mind is the small round engine cover found on the right-side of the FJ engine.

Last Friday, a computer-design-savvy friend stopped by the shop, and we rendered a ran a rough copy of the part in question. Naturally, we were a bit over-eager and ended up breaking the end mill during the roughing process. (kind of like breaking a drill bit in your drill)

Although our first attempt ended in failure, we were able to prove that the concept works.

Question/Discussion:
IF (and this is a big IF) we are able to perfect the design of this part, would members of the FJ community be interested in purchasing them?

Chris (the design guy) showed me how you can add text or design to a basic part rendering, and spit out the machine code to make the part. He actually made a rough sketch of the Yamaha tuning fork trio that could be either raised or relieved on the domed cover of the part. I was thinking of the possibilities, such as the name "FJOWNERS.COM" along with your forum user name, or the phrase "Polish Me, PLEASE", etc.

(Naturally, I would not want to get in trouble with the copyright-infringement police!)

So... if this sounds interesting to the masses, I'll set aside some of the appropriate scrap aluminum pieces. If no one seems interested, then I'll still pursue the learning experience, I just won't bother to keep any of the scrap around.

Thank you for your input, one way or the other.

Respectfully,

Steve  

[racerrad8]

You mean like one of these...?

Question/Discussion:
IF (and this is a big IF) we are able to perfect the design of this part, would members of the FJ community be interested in purchasing them?

That is a question I had not gotten around to asking yet.

Randy - RPM

[Steve_in_Florida]

You mean like one of these...?

Randy - RPM

Yes, SIMILAR to one of those!  <rolls eyes>

Certainly, I'm not looking to step on toes or take anyone else's profits. I just want to LEARN how to do stuff like this. The aluminum belongs to the owner of the shop, so I would need to reimburse him for the resources.

Just testing the waters...

Steve

[movenon]

Looks good. I think if I had any suggestion it would be to make it about 25mm thicker as it seems to serve as a "bumper" on a right side drop.  Mine was scoured when I bought it and of course I continued the process when I dropped it..... Also as a note a stock cover is or was available last time I checked.
Might consider a sacrificial urethane cap/bumper ?  Just crap in the campfire.
George

[RD56]

Does that piece cover the blind plug on the right side of the engine casing as you sit on the bike. Previous owner trashed mine. I'd buy it in a heartbeat.

Thanks, Rick

[RD56]

Looks good. I think if I had any suggestion it would be to make it about 25mm thicker as it seems to serve as a "bumper" on a right side drop.  Mine was scoured when I bought it and of course I continued the process when I dropped it..... Also as a note a stock cover is or was available last time I checked.
Might consider a sacrificial urethane cap/bumper ?  Just crap in the campfire.
George

Good idea George. not crap in the campfire.

Rick

[movenon]

Does that piece cover the blind plug on the right side of the engine casing as you sit on the bike. Previous owner trashed mine. I'd buy it in a heartbeat.

Thanks, Rick

Yes. Still available from Yamaha. Or at least a few months ago it was.
George

[FJ1100mjk]

Steve:

Since your cover idea was snagged by another enterprising entity already, soldier on with other ideas please. I have an idea, and perhaps others may have their own to spawn, to keep your creative juices flowing.

Is it possible to produce mirror extenders for the 84, 85 models? Could be a simple bar stock item with a male thread on one end that, threads into the existing female thread on the hand master cylinders, then have a horizontal 25mm offset with a female thread on the other end to match the mirror stalk's male thread.

Another idea for the mirrors, and to open possibilities of using other makes and model's mirrors is to produce adapters that thread into the existing aforementioned OEM FJ threads and have different female threads for other mirrors from other bikes.

Good luck!

[FJ1100mjk]

Is it possible to produce mirror extenders for the 84, 85 models? Could be a simple bar stock item with a male thread on one end that, threads into the existing female thread on the hand master cylinders, then have a horizontal 25mm offset with a female thread on the other end to match the mirror stalk's male thread.

http://fjowners.com/gallery/7/1388_23_06_14_7_16_55.jpeg

[aviationfred]

Great idea Steve 

I just happen to need one of those covers.....From Thursday afternoons aerobatics demonstration.

Fred

[movenon]

Great idea Steve  

I just happen to need one of those covers.....From Thursday afternoons aerobatics demonstration.

Fred

Take a look at these Fred. http://www.iwt-customparts.com/en/home.html?page=shop.browse&category_id=3
More ideas   
George

[racerrad8]

I think if I had any suggestion it would be to make it about 25mm thicker as it seems to serve as a "bumper" on a right side drop.  Mine was scoured when I bought it and of course I continued the process when I dropped it..... Also as a note a stock cover is or was available last time I checked.
Might consider a sacrificial urethane cap/bumper ?  Just crap in the campfire.
George

The cover will not work if made longer as it almost touches the engine bars now.

If you are not running engine bars I guess you could install longer cover, but I doubt the 4mm screws holding the cover on will take much of a shear load to protect the engine case when sliding down the road. Then there is still the question of the brake pedal pokes a hole in the clutch cover too.

The best protection you can buy are the engine bars found on the RPM website.

Randy - RPM

[Capn Ron]

I guess you could install longer cover, but I doubt the 4mm screws holding the cover on will take much of a shear load to protect the engine case when sliding down the road.

Randy - RPM

Yeah, when I did my low-side on the right-side, those two bolts sheared off instantly as if they were made of plastic!  The case wasn't damaged and a new cover fit right up.

[movenon]

I agree that the best protection are the Rentech engine guards.  No question about that.  I am thinking of making the best of an existing situation.  On the rear brake pedal I have trimmed mine back for more clearance and removed some of the sharp edge.  Still not going to protect much, but in a soft fall it might help and costs nothing.

You correct about the shear load of the 4mm bolts but I have seen a lot of caps ground down and the bolts are still there, also I have seen some completely gone.  If you don't have Rentech engine guards I still think a urethane cap would help.  I have thought about crash bungs/bumpers bolted to the frame also.

Now that I think about it a long narrow urethane cap/slider wouldn't be a bad add on to the side of the Rentec's. They seem to get ground in the same spot... On helicopter's we put "shoes" under the skids for practicing auto rotations on the taxi ways.

The Rentech engine guards are the best by far and I will buy a set when I can.  I have mentioned them to others and some like them and some don't like the looks and added weight,  for them there might be some other options to think about.
George

[Brook]

......http://www.fjowners.com/index.php?action=gallery;sa=view;id=2801

Steve, Could you do something like this [engrave a name or something on the front sprocket cover??]