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techtalk:ref:genmsr04a [2020/10/29 22:07] – created hippysmacktechtalk:ref:genmsr04a [2020/10/29 22:56] (current) – [Modifying a Rubber Stopper for Oil Tank Pressure Testing] hippysmack
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 ====== Modifying a Rubber Stopper for Oil Tank Pressure Testing ====== ====== Modifying a Rubber Stopper for Oil Tank Pressure Testing ======
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 +If you need a modded oil cap with a hose fitting for testing purposes, a rubber stopper can be modified to work. \\
 +The one below was modified to fit inside a 1998 Sportster oil tank (hole is tapered, app. 1.274" to app. 1.224"). \\
  
 +A rubber stopper can be purchased at local hardware stores. The one below was bought from Lowes. \\
 +The Hillman 4.6" black neoprene hole plug (taper 1-3/8" x 1-3/16") will work by simply drilling a hole through the center of it. \\
 +However, if it can't be found, the Hillman 1-5/8" x 1-5/16" x 1" can be slimmed down to work. \\
 +It is actually too big and the smallest part of the taper is all you can get into the oil cap hole. \\
 +
 +The 1-5/8" plug was used below. See the before and after pic below. The 1-5/16" end of the plug will go in the hole but not very far. \\
 +It is possible to simply hold it into the tank since it will go. But the one below was shaved to allow hands free operation. \\
 +
 +{{:techtalk:ref:genmsr:homemade_test_oil_cap_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\
 +
 +
 +The hole was drilled in three size stepped bits. \\
 +Then the fitting was clamped in a vise, the plug pushed hallway on the fitting and snugged up with a wrench. \\
 +To test how it would hold under pressure, 100 PSI was applied from the opposite side and the fitting popped out. \\
 +Another test was done after the fitting was reinstalled and it held app. 50 PSI well. \\
 +But, for testing crankcase pressure, you should be testing more than a 1-2 PSI anyway. \\ 
 +
 +{{:techtalk:ref:genmsr:homemade_test_oil_cap_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:ref:genmsr:homemade_test_oil_cap_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:ref:genmsr:homemade_test_oil_cap_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\
 +
 +The body was shaved by chucking the fitting into a drill and the plug was spun lightly on top of a rasp clamped in a vise. \\
 +Then the roughness was smoothed out by using steel wool wrapped around a file. \\
 +The fitting was pressed deeper into the plug during this process (not necessary but it happens). \\
 +This can now be used to test crankcase pressure in the oil tank. \\
 +
 +{{:techtalk:ref:genmsr:homemade_test_oil_cap_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:ref:genmsr:homemade_test_oil_cap_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:ref:genmsr:homemade_test_oil_cap_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\
  
  

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