CL alternator cover modified for SuperHawk

[Dick Eastman]

Since I'm not using the kick start, I found a CL alt. cover to modify, as it has two holes, instead of three. I cut the rear portion off, leaving only the clutch actuator bore. However, I did have to set the cases up to install two locator dowels. I turned up several alum plugs to the crank and tranny bearing diameters, so that I could assemble the gutted cases correctly located to one another to mount on the mill. There was enough case parting line on each end of the engine to butt against gage blocks in the t-slots to align the cases on the mill. I then trammed the crank plug for zero-zero, and then moved over to check the trans. bore for alignment. I then put the alt cover on and kept adjusting it till the stator bore and the clutch adjuster bore were in line with the crank bore and the trans. bore - I did this with an indicator. I left out the two screws that had the locator dowels under them, and snugged the other three screws. I then bored/reamed those two screw holes after indicating them in for coordinates, then removed the cover and bored the case in these two locations for dowels.. I set the alt cover up and re-bored the 10mm dowel holes, after picking up the previously reamed screw holes. Two turned step dowels were then made, and the case ass'y went back on the mill, alignment and zeroes established, and the alt. cover installed; I then checked the stator bore to the crank, and the clutch actuator bore to the trans., both were good.
The cases, btw, were vapor blasted for me by Vapor Honing Technologies in Connelly Springs, NC. They did my cylinder, head, two case halves, oil pump, valve cover, and cam end covers - very pleased with their work. They sell their own vapor blast cabinets, as well as do customer work-reasonable prices.

[G-Man]

Beautiful work, Dick!

Envious of your milling machine, space and skill....

G

Since I'm not using the kick start, I found a CL alt. cover to modify, as it has two holes, instead of three. I cut the rear portion off, leaving only the clutch actuator bore. However, I did have to set the cases up to install two locator dowels. I turned up several alum plugs to the crank and tranny bearing diameters, so that I could assemble the gutted cases correctly located to one another to mount on the mill. There was enough case parting line on each end of the engine to butt against gage blocks in the t-slots to align the cases on the mill. I then trammed the crank plug for zero-zero, and then moved over to check the trans. bore for alignment. I then put the alt cover on and kept adjusting it till the stator bore and the clutch adjuster bore were in line with the crank bore and the trans. bore - I did this with an indicator. I left out the two screws that had the locator dowels under them, and snugged the other three screws. I then bored/reamed those two screw holes after indicating them in for coordinates, then removed the cover and bored the case in these two locations for dowels.. I set the alt cover up and re-bored the 10mm dowel holes, after picking up the previously reamed screw holes. Two turned step dowels were then made, and the case ass'y went back on the mill, alignment and zeroes established, and the alt. cover installed; I then checked the stator bore to the crank, and the clutch actuator bore to the trans., both were good.
The cases, btw, were vapor blasted for me by Vapor Honing Technologies in Connelly Springs, NC. They did my cylinder, head, two case halves, oil pump, valve cover, and cam end covers - very pleased with their work. They sell their own vapor blast cabinets, as well as do customer work-reasonable prices.

[Dick Eastman]

Thanks, Graham.
A new cover I machined up to replace the original, which had a crack in it:

[G-Man]

Dick

Superb work. What is the finish on the main alternator cover? Makes it look very 'racer-like'.

Have you seen the conversions to lever clutch operation to replace that nasty screw thing? The CR72 uses a little bell-crank in there.

G

Thanks, Graham.
A new cover I machined up to replace the original, which had a crack in it:

[Dick Eastman]

Dick

Superb work. What is the finish on the main alternator cover? Makes it look very 'racer-like'.

Have you seen the conversions to lever clutch operation to replace that nasty screw thing? The CR72 uses a little bell-crank in there.

G

Thanks, Graham.
A new cover I machined up to replace the original, which had a crack in it:

Thanks- The main cover was bead-blasted, and was cleaned in a solution of OxyClean, which promptly turned the alum. darker, giving it the appearance of magnesium. I was prepping for paint, when I decided to machine some changes.
Where can I find info on clutch actuator mod? My screw actuator is actually very good condition, as it is part of the 2400 mile parts engine - don't think it ever had a blade in the slot. I did replace the actuator grease zert with a screw-in type for std grease guns.

[G-Man]

Dick

Interesting, I'll try and look out some pictures for you on the clutch mod.

Graham

Dick

Superb work. What is the finish on the main alternator cover? Makes it look very 'racer-like'.

Have you seen the conversions to lever clutch operation to replace that nasty screw thing? The CR72 uses a little bell-crank in there.

G

Thanks, Graham.
A new cover I machined up to replace the original, which had a crack in it:

Thanks- The main cover was bead-blasted, and was cleaned in a solution of OxyClean, which promptly turned the alum. darker, giving it the appearance of magnesium. I was prepping for paint, when I decided to machine some changes.
Where can I find info on clutch actuator mod? My screw actuator is actually very good condition, as it is part of the 2400 mile parts engine - don't think it ever had a blade in the slot. I did replace the actuator grease zert with a screw-in type for std grease guns.

[OldScrambler]

Very nice work. You also confirmed why I never throw-out a cracked or damaged case-cover. Because I generally work on the CL models, I was not aware of a different diameter between the CL and CB stator-covers.