See also Pics of Cam / Gearcase Cover Mods.

• Some helpful tool suggestions:
• For cutting the cover:
  • Saws-all.
  • Angle grinder with a metal cutting blade.
  • Jigsaw.
• To protect the aluminum from scratches while cutting:
  • Painters tape.
  • Soft jaws in a bench vise.
  • A towel to wrap the cover in before chucking into a bench vise.
• For holding the cover while cutting:
  • Bench vice.
• For shaping and smoothing:
  • Angle grinder.
  • Bench grinder.
  • Sander.
  • Hand files.
• For finishing:
  • Wet dry 220/400.
  • Steel wool.
  • WD-40.
  • Aluminum polish.

Cutting area marked out with tape. Cuts made with an angle grinder with the metal cut-off blade. 1)

Basic shaping done with the sander and files. (this can take several hours) 2)

The mounting holes were notched near the cut areas to make them all symmetric. The surface was finished with steel wool/WD-40 and aluminum polish 3)