The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Motor / Engine > Sportster Motorcycle Motor - Top End
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Sportster Motorcycle Motor - Top End Discuss Sportster Motorcycle Top End issues. Rockerboxes, Valves, Cylinders, Pistons, Rings, Lift Rods, etc...

Active Threads
0 Hottie of the day, no nudity.
Last Post: trainman
Posted On: 1 Minute Ago
Replies: 16,279
Views: 1,583,949
1 Pics of pets and what type of animals you have
Last Post: stikflote
Posted On: 7 Minutes Ago
Replies: 993
Views: 215,208
0 Long intake
Last Post: Nitro57xl
Posted On: 17 Minutes Ago
Replies: 37
Views: 567
0 Photo bucket
Last Post: 60Gunner
Posted On: 23 Minutes Ago
Replies: 11
Views: 138
0 Official XLForum Poll: What kind of bars are you running?
Last Post: Knuckles
Posted On: 28 Minutes Ago
Replies: 659
Views: 154,706
0 Had Kuryakyn Grips installed
Last Post: Tomcatt
Posted On: 28 Minutes Ago
Replies: 5
Views: 162
0 Ironhead 1000cc 1971 Help with clutch assembly
Last Post: needspeed
Posted On: 46 Minutes Ago
Replies: 2
Views: 42
0 Oil lines..
Last Post: Nitro57xl
Posted On: 1 Hour Ago
Replies: 9
Views: 273
0 Keep & Kill
Last Post: fafcpa
Posted On: 1 Hour Ago
Replies: 15,268
Views: 858,045
0 Hot Chicks on Hot Bikes
Last Post: hammer6315
Posted On: 1 Hour Ago
Replies: 10,523
Views: 1,878,701
0 Ironhead Oil Pump Gurus, come inside.
Last Post: kitabel
Posted On: 1 Hour Ago
Replies: 77
Views: 6,255
0 Which Battery?
Last Post: 60Gunner
Posted On: 2 Hours Ago
Replies: 48
Views: 14,749
0 Head work
Last Post: brucstoudt
Posted On: 2 Hours Ago
Replies: 4
Views: 222
0 More PhotoBucket Horrors...
Last Post: Bob F
Posted On: 2 Hours Ago
Replies: 27
Views: 2,014
0 My 1250 to 1275 build
Last Post: neilp
Posted On: 2 Hours Ago
Replies: 159
Views: 12,456
0 Electric Kick-Starter 2004- up Dumbest Idea EVER
Last Post: Folkie
Posted On: 3 Hours Ago
Replies: 4
Views: 119
0 Vote for Most Sought After Sportster
Last Post: doodah man
Posted On: 3 Hours Ago
Replies: 331
Views: 75,780
0 Oil, Filters and Spark Plugs
Last Post: glbsportster
Posted On: 3 Hours Ago
Replies: 65
Views: 2,641
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Bow only
Posted On: 3 Hours Ago
Replies: 46,157
Views: 7,311,273
0 Looking for updated 883 to 1200 info
Last Post: npaisnel
Posted On: 4 Hours Ago
Replies: 24
Views: 1,039
0 Show your favorite pic of your bike. just one
Last Post: Toro81
Posted On: 4 Hours Ago
Replies: 4,751
Views: 1,825,695
0 CV40 carb vac slide
Last Post: wedge
Posted On: 5 Hours Ago
Replies: 7
Views: 180
0 C.O.B.B. CBD oil
Last Post: mick42
Posted On: 5 Hours Ago
Replies: 21
Views: 969
0 Trans/Year Interchangeability Question
Last Post: ferretface
Posted On: 6 Hours Ago
Replies: 160
Views: 5,103
0 Banjo bolt sizes for front brake line.
Last Post: NLXL
Posted On: 6 Hours Ago
Replies: 19
Views: 372
0 TC88A update ?
Last Post: 60Gunner
Posted On: 6 Hours Ago
Replies: 31
Views: 451
0 1995 Sportster 1200, Black/orange, S&S, Supertrapp
Last Post: Toro81
Posted On: 6 Hours Ago
Replies: 33
Views: 3,941
0 Crusty's Travels
Last Post: Yakcm2
Posted On: 7 Hours Ago
Replies: 2,730
Views: 384,902
0 heat cycles
Last Post: Hippysmack
Posted On: 7 Hours Ago
Replies: 42
Views: 821
0 Glyptal?
Last Post: Iron Mike
Posted On: 8 Hours Ago
Replies: 13
Views: 351
More...
Members Birthdays
Sponsored Links
Reply
 
Share Thread Tools Display Modes
  #81  
Old 12th December 2019
Blue Scoot's Avatar
Blue Scoot Blue Scoot is offline
Chief Master Mechanic
 
Join Date: Jul 2013
Location: Phoenix, AZ
Posts: 479
Sportster/Buell Model: XL883N
Sportster/Buell Year: 2013
Reputation: 288928
Blue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond repute
Default

After looking at Time-sert vs helicoil I would rather use a Time-sert and be done with it. When I get home tonight I will be measuring the depth of the two center holes and look at which kit might work best as far as depth.



Sent from my BlackBerry
__________________
2013 Iron 883 currently @110k miles and counting...
Reply With Quote
Sponsored Links
  #82  
Old 12th December 2019
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,419
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

Take pics, we'd like to see the progress.

edit:
These are ReddTigger's pics with time serts.
It does appear to be on the left side however. Those holes are farther apart than the right side.







__________________
Reference the XLFORUM'S Sportsterpedia for additional technical information & advice

In Search of Fuel, Sunshine and a Steady Idle.

Last edited by Hippysmack; 12th December 2019 at 01:17..
Reply With Quote
  #83  
Old 13th December 2019
Blue Scoot's Avatar
Blue Scoot Blue Scoot is offline
Chief Master Mechanic
 
Join Date: Jul 2013
Location: Phoenix, AZ
Posts: 479
Sportster/Buell Model: XL883N
Sportster/Buell Year: 2013
Reputation: 288928
Blue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond repute
Default

So I did some measuring. Looks like the threaded portion of the studs are just under 1 inch- 0.936" and the hole in the case at its shortest point is 1.335"

So it looks like the shorter Timesert kit is the one to go with.

It says the inserts are .900"Long. Seems like that should be a really good fit.

Hippy the holes on the right side case definitely are closer together than the left side case.

I think I'm going to order that kit with additional inserts so I can practice a few before going for it.

Before I order it though any other suggestions from anyone?

Sent from my BlackBerry
Reply With Quote
  #84  
Old 13th December 2019
ReddTigger's Avatar
ReddTigger ReddTigger is offline
XL FORUM LIFE MEMBER
 
Join Date: Aug 2005
Location: MARY Lund, YUK !
Posts: 15,471
Sportster/Buell Model: XLH-1208
Sportster/Buell Year: 1997
Reputation: 2599297
ReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond repute
Default

Quote:
Originally Posted by Blue Scoot View Post
So I did some measuring. Looks like the threaded portion of the studs are just under 1 inch- 0.936" and the hole in the case at its shortest point is 1.335"

So it looks like the shorter Timesert kit is the one to go with.

It says the inserts are .900"Long. Seems like that should be a really good fit.

Hippy the holes on the right side case definitely are closer together than the left side case.

I think I'm going to order that kit with additional inserts so I can practice a few before going for it.

Before I order it though any other suggestions from anyone?

Sent from my BlackBerry

USE kerosene or wd 40 for drilling into aluminum.



i used a red loctite
__________________
States I've Ridden in

71.3 hp 70.8 tq

1208cc 11.09:1 (Wiseco 10° Dome 10.5:1 .010 over) ,Screamin Eagle Dual Plug Heads (10° 61cc), Original SE A/C, Vance & Hines Straight Shots w/ Custom Baffles. SE 6800 ign, Dual BREMBO brakes/ Pirelli Night Dragon MU85-16 Rear - 100/90-19 Front. Progressive Springs & 412 HD 13½" Chrome Shocks, 5½" pullback riser w/ "reddtigger mount", Stebel Nautilus Compact Air horn, Mustang Vintage Super Wide Touring Seat, Alto Carbonite Clutch
Reply With Quote
  #85  
Old 14th December 2019
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,419
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

Quote:
Originally Posted by Blue Scoot View Post
So I did some measuring. Looks like the threaded portion of the studs are just under 1 inch- 0.936" and the hole in the case at its shortest point is 1.335"

So it looks like the shorter Timesert kit is the one to go with.

It says the inserts are .900"Long. Seems like that should be a really good fit.

Hippy the holes on the right side case definitely are closer together than the left side case.

I think I'm going to order that kit with additional inserts so I can practice a few before going for it.

Before I order it though any other suggestions from anyone?

Sent from my BlackBerry
Yes the right threads are closer together and that's my biggest concern.
If it wasn't for the fact that those two holes lead to each other, it would be a lot easier to account for.

For those who have done this 100 times, it doesn't take long to do this task.
Setup is the longest part.
A lot of these things come second nature, but I figured I'd go through some check lists, hopefully remembered correctly.
I haven't ever done an insert repair to case head bolt threads although I chase them with a tap whenever the jugs are off.

Great idea to practice first. You need some flat stock aluminum comparable to the case material although that'd be hard to find.
Machine shops usually have plenty of scraps and may give a decent piece of aluminum to practice on.
Don't practice on iron / steel. It'll do you no good for learning for this application.
When you get the first hole done in practice, run a long test bolt into the hole down snug in the scrap sheet and use a speed square to measure several sides and see if the bolt is going to run straight
You can also run a short bolt into it to check if the underside of the head is flush with it when snugged up. That may be better.
Store bought bolts have a tendency to be warped / bent or other so that's not gonna be rocket science there especially longer ones but it happens on short ones also.
Repeat practice holes until you get that warm fuzzy.
When you start working on the case, don't flinch, trust yourself and just do it (after you've practiced of course).

Double check that the insert lengths will allow you to achieve depth on those two middle holes on the right case.
Calculate how much meat you're gonna have left between those two hole's inserts (OD edge to OD edge).
The inserts will need some meat between them (somehow).

Pack the Hell out of all crevices so you don't get shavings in the engine.
Packed / sealed well enough, blow all chips away with compressed air so they don't fall back into the engine once the packing is removed.

Drill straight but not too deep (90 degrees from the case).
Measure (twice) for the depth needed and mark that depth on the drill bit as a depth gauge.
You only need to drill to the depth of the insert.
Account for the chamfer on the end of the drill bit. The chamfered portion can not be included in your depth measurement.
Use a flat end bushing as a guide to help get a straight 90 degree hole.
Store bought bushings you'll find will not all be flush on the end.
Buy a few to compare for the most flush one you can find gauge from speed square or other on various sides.

Tap the threads straight with a bushing to help keep the threads 90 degrees to the case.
A bottoming tap should be included with the kit (the tapered end is barely noticeable compared to a tapered tap).
If not wait and buy one.
Don't try to tap all the threads per 1 hole at once.
Use some lube on the tap, preferably thick to cut with and thin to hose down the chips from the tap periodically.
You can use compressed air or brake cleaner to clean the drill bit and tap periodically also.
1/4 to 1/2 turns and back it out. clean, lube the tap and go back in.
Heat will be created while tapping so keep the tap lubed well.
Failure to lube the tap can lead to jagged cut threads and you'll be adding more damage pics to this thread later.
Reply With Quote
  #86  
Old 14th December 2019
ReddTigger's Avatar
ReddTigger ReddTigger is offline
XL FORUM LIFE MEMBER
 
Join Date: Aug 2005
Location: MARY Lund, YUK !
Posts: 15,471
Sportster/Buell Model: XLH-1208
Sportster/Buell Year: 1997
Reputation: 2599297
ReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond reputeReddTigger has a reputation beyond repute
Default

a good investment..

one of these. will all but guarantee a straight hole. if you don't have a press and etc.. like i did .

Reply With Quote
  #87  
Old 14th December 2019
Tomcatt Tomcatt is offline
Dazed & Confused
 
Join Date: Feb 2019
Location: Never Never Land
Posts: 809
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2017
Other Motorcycle Model: BMW R Nine T
Other Motorcycle Year: 2015
Reputation: 1085783
Tomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond reputeTomcatt has a reputation beyond repute
Default

Quote:
Originally Posted by ReddTigger View Post
a good investment..

one of these. will all but guarantee a straight hole. if you don't have a press and etc.. like i did .

aka "drill block". It will help to have a second pair of hands and eyes while you're drilling.
__________________
2017 XL1200C in Wisconsin, USA
Reply With Quote
  #88  
Old 14th December 2019
Blue Scoot's Avatar
Blue Scoot Blue Scoot is offline
Chief Master Mechanic
 
Join Date: Jul 2013
Location: Phoenix, AZ
Posts: 479
Sportster/Buell Model: XL883N
Sportster/Buell Year: 2013
Reputation: 288928
Blue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond repute
Default

Thanks Hippy, Red and Tomcat

That is all some really good advice. The biggest part of this will have to be patience and attention to detail.

I will be ordering the Timesert kit today and looking for a drill block as well.

I will keep this thread updated as I go the best I can. Thanks again to every one, I really appreciate all of the help!

Sent from my BlackBerry
Reply With Quote
  #89  
Old 2 Weeks Ago
Blue Scoot's Avatar
Blue Scoot Blue Scoot is offline
Chief Master Mechanic
 
Join Date: Jul 2013
Location: Phoenix, AZ
Posts: 479
Sportster/Buell Model: XL883N
Sportster/Buell Year: 2013
Reputation: 288928
Blue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond reputeBlue Scoot has a reputation beyond repute
Default

UPDATE:

Ok so I had ordered the Time-Sert kit for the cylinder studs and got some extra inserts as well.

I even got a tap guide for using with the kit that will help to keep the tap in line.

However, the biggest concern I have is going to be when drilling the threads out and keeping the drill bit where it needs to be so I don't mess this up.

I even ordered a few different size tap guides to try but the drill bit is such an odd size even a drill block didn't seem to work.

I'm going to try and find a metric drill block because the drill bit seems to be about the same size as an M10 hardware.

But other than that I think that's everything I will need to have on hand to get this done.

I will take photos as much as I can and update as I get started with this project.

Sent from my BlackBerry
Reply With Quote
  #90  
Old 2 Weeks Ago
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,419
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

You're going to have to hold tight to the guide with one hand and the drill with the other.
Not the best scenario but if you use a bushing, same thing.
If you clamp it with pliers / vise grips, you'll egg shape the bushing, possibly catching the bushing on the bit and spin it, marring up the cylinder mating surface.

Keep in mind the guide / bushing is only there to give you a visual of a 90 degree plane.
If you size the bushing too small of ID, the bit can catch on it if you lean one way or the other.
Once the bit gets inside the hole and starts cutting thru the threads, it'll follow that hole.
All you want to do is make sure the bit stays centered as it follows the hole.
You're not going to get anywhere close to a precision hole with a hand drill.
Reply With Quote
Sponsored Links
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



Sponsored Links
All times are GMT +1. The time now is 01:41.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2020, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC