Shadow Build

[John H]

Making a woodruff keyway in a tapered bore could be done manually but kinda slow. A standard woodruff broach would require a custom bushing that fit the tapered bore. Most machine shops have standard broaches. The trick would be getting the tapered bushing slotted to the correct depth so the broach makes the keyway the correct depth. Does the shaft already have a woodruff key in it? If so, what size.

[Lotus54]

Yes, the shaft does have a key. I think 2mm wide.
The original flywheel is keyed.

[John H]

If you get a 2mm broach I think we can make the tapered bushing for it.

[Lotus54]

That would be fantastic. I will see how it goes- but I would feel better with a key. So I will start sourcing a 2mm broach

[John H]

For a one time use try Ebay, about 20 bucks.

[John H]

Not much happening on the project right now. I did repair the magneto cover which had been improperly repaired before.

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Here I'm fitting the feed and return oil pipes. Normally they don't fit this close to the covers but with a bit of metal removal they will fit snugly.

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[Lotus54]

Looking great!

[John H]

More oil lines that lubricate the rockers. They are in bad shape so next step will be replacing the copper tubing between the brass fittings. It will be a bit tricky as it appears to be silver brazed so the old copper may have to be drilled out of the fittings. Not looking forward to that. May have to strip the chrome off first.

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[John H]

More nuts, bolts and screws are cleaned, machined and sanded in preparation for cad plating. A boring job but will look nice when installed. These are British fasteners with an assortment of varied thread pitches from 19tpi to 26tpi. Once plated all the threads will need to be chased so everything goes together smoothly.

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[Lotus54]

Nothing like a bunch of different thread pitches…

Are you setup to do cad plating? Back in the Dental Lab days we would plate things maybe twice a year. I imagine the power supply is still around and probably some solution.