DIY Clutch window

[Klause]

Making a clutch window for my Monster
Been toying the idea for a while and came across a clutch cover at BMF show for £20 bargin, so who cares if it fu*ks up .

I asked for advice in the workshop section for what window material to use and lexan seemed to be the thing to use. Ordered an a4-a3 ish sized sheet 5mm thick for £9.

The sheet arrived today. So armed with some new drill bits and a dremel I set off...

Drilled holes all the way around the inside of the circle, then took the dremel and cut inbetween the gaps, went through 4 bloody cutting discs!
https://img207.imageshack.us/img207/7836/dscf16334dt.jpg

Spent a while filing it all even but I was doing this all by free hand so not perfect.

Doesn't look to bad now...
https://img136.imageshack.us/img136/9273/dscf163618ye.jpg

Just cutting the lexan now and shall hopefully have pictures of it finished later.
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Current bikes: 1960 Triumph 5ta x2, TTR600RE, KTM200EXC, Cagiva Elephant 900ie.

[T1z3R]

like windows in PC cases but better
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duck my sick!

[Klause]

Maybe I should fit LED's inside the engine just like PC's... nah lol.

Having trouble sealing the window now, off halfords to find some better sealing gluey stuff.
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Current bikes: 1960 Triumph 5ta x2, TTR600RE, KTM200EXC, Cagiva Elephant 900ie.

[Klause]

Pants... I put the lexan in and used some sealant and some chemical metal in places to make a strong joint. I tested it by putting oil in the case and left it, it lasted about 1hr before it leaked. Need to find where it's leaking from and stuff more sealant in.
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Current bikes: 1960 Triumph 5ta x2, TTR600RE, KTM200EXC, Cagiva Elephant 900ie.

[Deano]

if this turns out alrite Im tempted to try it myself

[Wave2k]

ahhh the joy of dry clutches .
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Ducati 1299 Panigale
2009 Corvette C6 z51
RS125->CBR400->RXS100->GSXR750K2->Ducati749S->CBR600RR5->TL1000R->DRz400->RSVR1000->Honda VTR SP1->CBR400->GSXR1000K6->Honda H100->CBR600RR3->Ducati1299

[Barry_M2]

[trevoriv]

Is it not going to be under different kinds of pressure when the engine is running though

[Jenks]

That looks fairly good.

Good luck with it - As it progresses!

Keep us informed!

[Klause]

Trying to find a suitable sealing/joining compound at the moment.
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Current bikes: 1960 Triumph 5ta x2, TTR600RE, KTM200EXC, Cagiva Elephant 900ie.

[Irezumi aka Reuben]

Would some form of riveting not work?
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Pictorgraphicalfantastical

[Zimbo]

[Klause]

I've considered all this, but after drilling and dremeling the clutch cover I would hardly say that was strong either, it was made of cheese this lexan stuff seems stronger.

[McJamweasel]

[Zimbo]

That's what I meant, I wasn't suggesting the Lexan would break (unless mashed up in the engine) but it won't take a lot to break the seal, which may have (indeed, probably would have)catastrophic results.
If you're doing 70 or 80 mph and the seal goes, you're unlikely to notice the oil disappearing, you probably won't see the oil light immediately either, the first you're likely to know about it is a sudden and dramatic loss of power as the engine self destructs about 20 seconds later. It could easily have you off (engine sieze plus rear wheel covered in oil = potential very nasty accident) and you're looking at a scrap engine even if you don't come off, throw the whole thing away and buy a new one.
It's your bike of course, but personally I'd say the risks are far too high to justify the project.

[DaveH]

If the lexan is cut to the full diameter of drilled face of the clucth cover, not just slightly bigger than the hole, it looks as though there will be enough room for a couple of bolts - with the heads on the inside and the nuts loctited on?

good luck

BTW how much clearance is there between the clutch and the housing?

[Deano]

[DaveH]

[senna_f4]

Sorry guys, nice project, but I fear it may be more complicated.
Why?
1. Aluminium expands more than lexan (plastic)
2. Rigid joint

1+2 = warm up bike and pop goes your joint or lexan or case.

The aluminium will case will grow big, so the joint must be able to slide laterally, that is a movement along the face of the lexan window.

Hope it helps
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"You don't know the power of the dark side."

[Zimbo]

[McGee]

Dont listen to the negative people, give it a go


And zimbo its a dry clutch
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◙◙► K6 GSXR 600 ◄◙◙◙◙► K5 GSXR 1000 ◄◙◙◙◙► K5 GSXR 600 ◄◙◙◙◙► 96 RF600r ◄◙◙
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Its pronounced Jixxer!

[Zimbo]

[McGee]

Actually he done an engine transplant if im right cant remember what to though think its a 750 ?
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◙◙► K6 GSXR 600 ◄◙◙◙◙► K5 GSXR 1000 ◄◙◙◙◙► K5 GSXR 600 ◄◙◙◙◙► 96 RF600r ◄◙◙
◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►
Its pronounced Jixxer!

[Zimbo]

Still a wet clutch though. The cover shown in the pics is for a wet clutch engine, the dry clutch engine casing is completely different.

[Klause]