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techtalk:ref:tools107 [2019/01/20 02:01] – [Reamers] hippysmacktechtalk:ref:tools107 [2024/01/23 03:43] (current) – [Bushing Installation] hippysmack
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 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]] [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
 ====== REF: Tools - 107 ====== ====== REF: Tools - 107 ======
-====== Cam Bushing Removal Tools ====== +====== Cam Bushing Measuring / Removal / Installation Tools ====== 
-===== Bushing Removal =====+\\ 
 +====== #2 Cam Gear Press ====== 
 +A gear puller shaft attached to a bearing separator for pressing the gear on #2 cam.  \\ 
 +|Gear press for #2 cam gear. ((photo by jstoll of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-project/182089-jak-stolls-xl1200f-frankenbike?t=1961921))|  
 +|{{:techtalk:ref:tools:gear_press_for_2_cam_by_jstoll.jpg?direct&250|}}|
  
 +====== Measuring the Bushings ======
 +|  Measuring Cam Bushinhgs. ((photos by AussieGazza of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/87710-aussiegazzas-rebuild/page5?t=692835&page=5))  |||
 +|{{:techtalk:ref:tools:measuring_cam_bushings_1_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:ref:tools:measuring_cam_bushings_2_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:ref:tools:measuring_cam_bushings_3_by_aussiegazza.jpg?direct&300|}}|
  
 +====== Bushing Removal ======
   * You can buy different brands but this is basically a slide hammer with an expandable collet. \\ See also [[techtalk:ref:engmech01g|Cam Bushing Removal]] in the Sportsterpedia.    * You can buy different brands but this is basically a slide hammer with an expandable collet. \\ See also [[techtalk:ref:engmech01g|Cam Bushing Removal]] in the Sportsterpedia. 
  
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 |{{:techtalk:ref:tools:98_1200_cam_bushing_removal_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_1_by_hippysmack.jpg?direct&300|}}| |{{:techtalk:ref:tools:98_1200_cam_bushing_removal_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_1_by_hippysmack.jpg?direct&300|}}|
  
-|Also check local auto parts stores for a pilot bearing puller. \\ This works basically the same as the slide hammer except it pulls the bushings out instead of knocking them out. ((photos by 62 Ironhead of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=2))||| +|Check local auto parts stores for a pilot bearing puller. ((photo by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page2?t=1717904&page=2))| 
-|{{:techtalk:ref:tools:pilot_bearing_puller_1_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_2_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_3_by_62_ironhead.jpg?direct&300|}}|+|{{:techtalk:ref:tools:pilot_bearing_puller_1_by_62_ironhead.jpg?direct&300|}}|
  
-===== Modified Cover for Reaming =====+|This works basically like the slide hammer except it pulls the bushings out instead of knocking them out. ((photos by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page2?t=1717904&page=2)) ||For smaller bushings, grind the back of the jaws a \\ little so they close more to fit the smaller space. ((photo by decman of the XLFORUM https://www.xlforum.net/forum/general-area/off-topic-general-discussion/166860-this-week-in-my-shop/page7?t=1793066&page=7))| 
 +|{{:techtalk:ref:tools:pilot_bearing_puller_2_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_3_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_by_decman.jpg?direct&300|}}|
  
-|  Modified cam covers for reaming ((left photo by decman of the XLFORUM http://xlforum.net/forums/showthread.php?postid=5016753)) ((right photo by Hippysmack))  || +**Homemade bushing remover**: \\ 
-|{{:techtalk:ref:tools:modified_cam_bushing_cover_for_reaming_by_decman.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_4_by_hippysmack.jpg?direct&300|}}|+The puller is made from 1" ID black pipe and 1/2"-13 threaded rod. You tap the flex head-puller head through the cam bearing. \\ 
 +The little nub puller with a collar that you knock into the bearing is made from 3/4" rod. Then screw the rod into the head to tighten the jaws. \\ 
 +Then place the collar over the rod and nut to start the pulling. \\
  
-|The bushing holes were drilled thru for -access into and thru the cover bushings to the case bushings. ((photos by decman of the XLFORUM http://xlforum.net/forums/showthread.php?postid=5016753))|| +4 grooves were cut into the end for flex / compression to push through the bearing. \\ 
-|{{:techtalk:ref:tools:modified_cam_bushing_cover_2_for_reaming_by_decman.jpg?direct&300|}}|{{:techtalk:ref:tools:modified_cam_bushing_cover_3_for_reaming_by_decman.jpg?direct&300|}}| +Then it was center drilled 7/16" and tapped 1/2"-13 and the slots were cut with a 3/16" end mill. \\ 
-===== Reamers ===== +The threaded rod causes outward pressure on the jaws of the head when pulled. ((photos by fergerburger of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129325-cam-chest-tools-made-tonight))  
-**Cam cover bushings**: \\ +\\ 
-The reamers for the cam cover bushings (#1, #3 and #4) need to be chamfered (chucking) reamers. \\ +|{{:techtalk:ref:tools:homemade_cam_bushing_tools_1_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_2_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_4_by_fergerburger.jpg?direct&300|}}|
-The ends have a short chamfer that will enter the blind bushing bore and not hit the rear of the bore before finished cutting the bushings. \\ +
-The reamer for #2 cam can be a tapered bridge reamer on models with nosecone ignitions. \\ +
-(the hole for #2 cam is open  to atmosphere so the reamer has plenty of room to extend past the bushing) \\ +
-Else it will also need to have a chamfered end. \\+
  
-Cam cover reamer sizes: \\+|{{:techtalk:ref:tools:homemade_cam_bushing_tools_5_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_6_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_7_by_fergerburger.jpg?direct&300|}}|
  
-9/16" for the pinion shaft bushing. \\ +====== Bushing Installation ====== 
-1-1/8" for #2 cam bushing. \\ +These are typically knocked in with a commercially available long rod and a hammer. \\ 
-11/16" for #1, #3 and #4 cam bushings. \\+Below are a couple homemade tools for installing the bushings. A knocking rod and a compression plate. \\
  
-**Case bushings**: \\ +The knocker rod is made from 1" aluminum bar stock with a .030" shoulder to recess into the bearing, .030" into the case. ((fergerburger of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129325-cam-chest-tools-made-tonight?t=1349714)) \\
-A single reamer is all that is needed for the case side bushings as all the cam bushings are the same size in the case. \\ +
-The normal way of reaming the case bushings is to split the case and ream case bushings by using the cover bushings as a guide. \\ +
-This will require a bridge reamer with a tapered end. \\+
  
-If reaming the case bushings from the outside of the cover bushings, you'll need a chamfered (chucking) reamer with a short chamfer. \\ +The compression plate is made from a scrap steel plate. The bolts screw in to push the bushings in place. See the [[techtalk:ref:tools107#reverse_engineered_cam_bushing_installer|build pics]] below by Hippysmack. \\
-The long taper will go in and touch the flywheel before the blades have a chance to cut into the reamer. \\ +
-So reaming the case side bushings will not be possible with a bridge reamer from the outside of the cover.+
  
-Case bushing reamer size: \\+{{:techtalk:ref:tools:homemade_cam_bushing_tools_3_by_fergerburger.jpg?direct&300|}} ((photo by fergerburger of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129325-cam-chest-tools-made-tonight?t=1349714)) {{techtalk:ref:tools:cam_bushing_installer_41_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{techtalk:ref:tools:cam_bushing_installer_39_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) 
  
-11/16" for #1-#4 cam bushings. \\+===== Modified Cover for Reaming =====
  
-|  Cam bushing reamers ((photo by decman of the XLFORUM http://xlforum.net/forums/showthread.php?postid=5016753))  | +|  Modified cam covers for reaming ((left photo by decman of the XLFORUM https://www.xlforum.net/forum/general-area/off-topic-general-discussion/166860-this-week-in-my-shop/page6?postid=5016753#post3644788)) ((right photo by Hippysmack))  || 
-|{{:techtalk:ref:tools:cam_bushing_reamers_by_decman.jpg?direct&300|}}|+|{{:techtalk:ref:tools:modified_cam_bushing_cover_for_reaming_by_decman.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_4_by_hippysmack.jpg?direct&300|}}| 
 + 
 +|The bushing holes were drilled thru for -access into and thru the cover bushings to the case bushings. ((photos by decman of the XLFORUM https://www.xlforum.net/forum/general-area/off-topic-general-discussion/166860-this-week-in-my-shop/page6?postid=5016753#post3644788))|| 
 +|{{:techtalk:ref:tools:modified_cam_bushing_cover_2_for_reaming_by_decman.jpg?direct&300|}}|{{:techtalk:ref:tools:modified_cam_bushing_cover_3_for_reaming_by_decman.jpg?direct&300|}}| 
 + 
 +===== Reamers ===== 
 +See [[techtalk:ref:tools147#cam_bushing_reamers|Cam Bushing Reamers]] in the Sportsterpedia. \\
  
 ====== Reverse Engineered Cam Bushing Installer ====== ====== Reverse Engineered Cam Bushing Installer ======
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 I decided to make my own bushing installation tool since I have checked with the MOCO in three states and nobody has the one mentioned in the FSM for sale. A bushing hammer would have worked fine but I didn't want to beat the cam bushings in my engine. Besides, I wanted to use the shop. The plan is to make an installer, press the bushings in with it and ream the bushings thru a spare and molested cam cover. I'm doing this backwards from the FSM. Your suppose to ream the bushings to exactly 11/16" at a right angle, place the cover on the case half (which has been split from the left case half) and then ream through from the case half into the cam cover with a pilot reamer. I have a reamer that is 11/16" dia from one end to the other and the cutting blades are over 3" long. I decided to make my own bushing installation tool since I have checked with the MOCO in three states and nobody has the one mentioned in the FSM for sale. A bushing hammer would have worked fine but I didn't want to beat the cam bushings in my engine. Besides, I wanted to use the shop. The plan is to make an installer, press the bushings in with it and ream the bushings thru a spare and molested cam cover. I'm doing this backwards from the FSM. Your suppose to ream the bushings to exactly 11/16" at a right angle, place the cover on the case half (which has been split from the left case half) and then ream through from the case half into the cam cover with a pilot reamer. I have a reamer that is 11/16" dia from one end to the other and the cutting blades are over 3" long.
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   * My cam bushings turned out to be .005" out of service limit in the right case half. So, I yanked them out with the HF tool above.   * My cam bushings turned out to be .005" out of service limit in the right case half. So, I yanked them out with the HF tool above.
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