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HOW2: Make a Cornflake Paket Gasket!

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SnowTigeress
Brolly Dolly



Joined: 23 May 2010
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PostPosted: 00:22 - 11 May 2011    Post subject: HOW2: Make a Cornflake Paket Gasket! Reply with quote

I had to clean the oil strainer on the Super-Dream, and fit a new clutch today.
This meant i had to take the primary drive cover off. Only problem was that I couldn't find any one that sold individual gaskets, and when Tef took me to the local car spares shop for some propper gasket paper, they hadn't got any. So Tef said to use a Cornflake packet!

I had heard of this, and thought it was a real 'Bodge', but Tef assured me that done 'properly' its actually a well renouned 'improvised repair', and used to be one of the first things aprentice mechanics were tought... so here goes! My first attempt at making my own gasket from paper... or Cerial packets!

You will need:
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/100_0525.jpg

* A cerial packet! Apaently cornflake Pakets are best, but we aren't that posh, but we this girl was undaunted. I had my Wheetabix this morning! LOTS of them! I needed the empty box! Has to be bigger than the cover or whatever you are making a gasket for BTW.
* A hammer to make a 'rubbing' of the cover to get an impression to cut to on the paper.
* The screws or bolts that hold the cover on, so that you can hold it in place while marking & cutting
* A craft knife or two
* Pair of scissors

Tef says "START WITH THE HOLES!"
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/100_0528.jpg
Placing the cardboard over the cover, find one hole, and mark it with a screw, pushing through the cover against the paper. Tef says DONT get carried away. You start with ONE hole, and get it 'right'.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/100_0527.jpg
So you cut a SMALL cross in the paper, then push a screw through and cut the feathery bits it pushes up, off, cutting against the screw. Its a lot easier and more accurate then trying to cut a circle free hand!
You start with the holes, because, they are the awkward bits. He reckons lots of people... like I tried to.... start by cutting the outline first, then the big gap in the middle, then try punching the holes through and find they tear the gasket and have to start all over, or they get the outline all out of shape!
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2044.jpg
You start with the holes, cut one, get it good, then line the paper back on the case and do another RIGHT on the other side of the case to get the paper lined up... THEN you can go round and mark the other holes, and cut them.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2045.jpg
With all the holes done, you can then use the screws to hold the cardboard in place, to stop it shifting around and giving you a distorted outline, while you rub the hammer over the shiny side of the cardboard, to get an impression of the outline on the soft side.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2046.jpg
With the rubbing 'done' you can then start cutting the outline. In the case of the Super-Dream / Benley engine, there is a niggly oil gallery in the casing.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2047.jpg
Tef said start by cutting the smaller apertures first, as the more paper there is around them, the better supported they are, and the easier it is to make them accurately, and not tear the paper.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2048.jpg
Cutting with a craft knife, often wont go all the way through the paper, and pressing harder, can risk cutting into the bits you want to keep. But once you have got the like you want scored, you can normally work it through from the other side, to pop out the unwanted bit. But don't cut too thin! Don't worry about making it exactly accurate, working off the case, just rough out the middle you want to take out, but leave a little trim space to take off to neaten it up 'on' the case.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2049.jpg
The aperture can be trimmed accurately to follow the case, 'on' the case, pinned down again with the bolts to hold it steady
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2052.jpg
Then the same process can be repeated to take out the larger sections or apertures.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2053.jpg
Care is needed on thinner sections, where there is a lot of space between the bolts holding the paper to the case, or there is a complicated shape.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2054.jpg
In these places, best to hold the paper to the case, either side of the blade, being careful of your fingers!
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2056.jpg
With all the internal areas cut out and trimmed, with the paper pegged down on the case again, FINALLY the outside can be cut to shape.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2058.jpg
And here it is. One Cornflake packet gasket, all ready to seal the primary drive cover on the engine!
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2059.jpg
This is a first class, bit of budget mechanics! One bit of waste packaging and ten minutes work with a scalpel!
LOADS cheaper, and a lot safer, and less messy than squeezee gasket!

Ill be getting a fullgasket set when i do the engine rebuild after my tests
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stinkwheel
Bovine Proctologist



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PostPosted: 00:41 - 11 May 2011    Post subject: Reply with quote

Excellent post.

I've been using cereal packet gaskets for years and never had one leak. I've had a few made of "proper" gasket pepar leak.

You can use one most places there is a paper gasket. One thing to beware of is in gearboxes, they can be shimmed to a pretty fine tolerance so you need the correct thickness of paper gasket (proper gasket paper comes in various thicknesses). As a general rule, if the two parts you're sealing have a shaft running between them, it's probably better to use the correct thickness paper. Everything else, paper is fine. Including base gaskets.
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hmmmnz
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PostPosted: 03:10 - 11 May 2011    Post subject: Reply with quote

its gfunna fail, every one knows that it has to be made from acorn flakes packet, weetbix just won't cut it Very Happy

nocely done snowtigeress, been a tried and true method for a couple of geneations
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27cows
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PostPosted: 06:45 - 11 May 2011    Post subject: Reply with quote

Bloody hell, that takes me back to the good old days. Used to do this all the time. The secret of making the gasket last is to brush a little engine oil on to the card, leave it about an hour to absorb, then use. Never had one fail but I've not had cause to make one in a while now.
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Old Git Racing
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PostPosted: 08:08 - 11 May 2011    Post subject: Reply with quote

Nice one Thumbs Up

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SnowTigeress
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PostPosted: 08:48 - 11 May 2011    Post subject: Reply with quote

hmmmnz wrote:
its gfunna fail, every one knows that it has to be made from acorn flakes packet, weetbix just won't cut it Very Happy

nocely done snowtigeress, been a tried and true method for a couple of geneations



It will work for me, I had my weetabix`s (lots of them) so that I had an empty box to be able to make it.
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Rogerborg
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PostPosted: 11:09 - 11 May 2011    Post subject: Reply with quote

Proper craftwomanship, that.

That said, last time I took the clutch cover off my 305, I just cleaned the remains of the old gasket off then slapped some instant gasket gunge on, job's a good 'un. Embarassed
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Teflon-Mike
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PostPosted: 11:19 - 11 May 2011    Post subject: Reply with quote

hmmmnz wrote:
nicely done snowtigeress, been a tried and true method for a couple of geneations

And some!
Its roumoured I'm now a Grandad. I was toght to cut paper gaskets ny MY grandad, and he reckoned he was tought by his dad!
Rogerborg wrote:
Proper craftwomanship, that.
That said, last time I took the clutch cover off my 305, I just cleaned the remains of the old gasket off then slapped some instant gasket gunge on, job's a good 'un. Embarassed

Gloop on a 305's oil chamber..... Hmmmm...
Notoriouse oil pump gears; notoriouse oil pick up.......
.... and excess RTV jelly floating around in the oil...
This is either incredibly brave, incredibly daft, or bordering on the madness of genius.... I'm not sure!
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stinkwheel
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PostPosted: 11:31 - 11 May 2011    Post subject: Reply with quote

Teflon-Mike wrote:

Gloop on a 305's oil chamber..... Hmmmm...
Notoriouse oil pump gears; notoriouse oil pick up.......
.... and excess RTV jelly floating around in the oil...
This is either incredibly brave, incredibly daft, or bordering on the madness of genius.... I'm not sure!


Agreed. There's an oilway running along the join between that cover and the crankcase in a similar way to the one on this view of the CB125 one.

Only the 305 one has -for some bizarre and poorly thought out reason- a locating dowel IN the oilway.
http://i178.photobucket.com/albums/w269/teflons-torque/071_A_010_Gasket/imag2056.jpg
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I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Rogerborg
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PostPosted: 13:44 - 11 May 2011    Post subject: Reply with quote

Teflon-Mike wrote:
Rogerborg wrote:
That said, last time I took the clutch cover off my 305, I just cleaned the remains of the old gasket off then slapped some instant gasket gunge on, job's a good 'un. Embarassed

Gloop on a 305's oil chamber..... Hmmmm...
Notoriouse oil pump gears; notoriouse oil pick up.......
.... and excess RTV jelly floating around in the oil...
This is either incredibly brave, incredibly daft, or bordering on the madness of genius.... I'm not sure!


I hasten to add that it was a verrry small trail of gloop, laid near the outside edge of the surfaces, and I checked the nylon gear, circumcised the pick up tube, and will be doing another change, pump examination and fitting a proper gasket aaaany day now. But yes, there's a definite element of "Oil starvation? Come on then, let's have it" quixoticism to it. Very Happy
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Marmalade
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PostPosted: 06:20 - 19 May 2011    Post subject: Reply with quote

Had a thermostat housing gasget blow out on a transit on the motorway near munich.

Used a red bull cardboard sleeve and had to tear it out by hand as i had nothing to cut it with.

Gave it wings and it was still fitted and doing a fine job when I sold the van

http://i370.photobucket.com/albums/oo141/bramble43/trannybodge.jpg
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jack_p92
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PostPosted: 10:53 - 30 May 2011    Post subject: Reply with quote

would this work on a water pump? or would gasket maker be better?
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Piercee100
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PostPosted: 12:05 - 30 May 2011    Post subject: Reply with quote

I can remember swapping an engine on my old mk1 Escort with a mate and was about to toddle off to Halfrauds to buy a gasket set (only place open on a Sunday) and he stopped me and made a full set of gaskets out of Cornflake boxes. I thought he was taking the piss and was pretty upset at the time but it never failed.

Nice post Very Happy
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Piercee100
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PostPosted: 12:20 - 30 May 2011    Post subject: Reply with quote

Didnt have to make a headgasket as it was a complete swap but it was waterpump, thermostat etc. Those were the days Smile
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Amreet
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PostPosted: 20:01 - 31 May 2011    Post subject: Reply with quote

Vincent wrote:
If you want to save money, just buy a sheet of gasket paper.

Must have been good cornflake cardboard to make a full gasket set out of it. Head gasket must have been fun to make. Wink


hehe. I ran a mobylette on a paper headgasket for a few weeks. worked fine, just the exhaust fumes smelt of a really interesting burning. When I eventually put a proper metal job on, the paper was pretty singed but intact and holding well. still have it somewhere on my bench in the garage!
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SpannerMonkey
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PostPosted: 20:11 - 31 May 2011    Post subject: Reply with quote

Teflon-Mike wrote:
Its roumoured I'm now a Grandad

I would apologise for this... But I'm not sorry Razz
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Ed Case
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PostPosted: 21:42 - 31 May 2011    Post subject: Reply with quote

Vincent wrote:
If you do use a cornflake packet, don't use one for your alternator cover. I did once in an emergency after a crash in the middle of nowhere, (Wem), and the crank welded itself to the inside of the cover Embarassed


Yep, I know Wem and you're dead right, it's in the middle of nowhere. Smile
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