Well I reworked my sump that had a knackered plug.
The sump had already been strippend and rebored to 18m with a helicoil fitted by the previous owner.
The helicoil didn't hold in such a shallow bore so I had to think of something else.
Had I known the sump was ribbed on the inside like it is I may have considered another approach,
however the haynes manual shoved a sump with a smooth inside face. It lied.
In the end I used a pillar drill and some old router bits to machine the inside face of the sump flat.
I then used a hole saw bit to bore a 20mm hole through the sump.
Finally I used the router again to machine the outer lip off of the sump.
With this now flat working area I fitted a 15mm tank connector I'd acquired at a plumbers merchants.
It has a flat backing plate that gripth the inside of the sump against a large flat nut on the outside of the sump.
Lastly I used a matching blanking cap, also from the plumbers merchants, to seal the sump until it needs drained.
I feel the plates on the tank connector ought to reinforce the milled out aluminium enough.
The tangs on the inside face of the sump stick up about 2mm higher than the aluminium wals near them do,
but there is still plenty of clearance
The pieces
(Left to right; Blanking cap, securing nut, outside washer, secondary o-ring, main piece with o-ring)
(http://img.photobucket.com/albums/v290/red_Phil/Bike_work/sump7.jpg)
The machined inside face
(http://img.photobucket.com/albums/v290/red_Phil/Bike_work/sump5.jpg)
The machined outside face
(http://img.photobucket.com/albums/v290/red_Phil/Bike_work/sump6.jpg)
Inside view of new fitting in place
(http://img.photobucket.com/albums/v290/red_Phil/Bike_work/sump8.jpg)
Outside view before securing nut tightened
(http://img.photobucket.com/albums/v290/red_Phil/Bike_work/sump1.jpg)
Outside view with blanking cap off
(http://img.photobucket.com/albums/v290/red_Phil/Bike_work/sump4.jpg)
The finished job
(http://img.photobucket.com/albums/v290/red_Phil/Bike_work/sump9.jpg)
Wow, impressive! Good work!
:nono:
I have been reminded to mention my lovely assistant who helped me in this endevour.
The lovely Tina. :mrgreen:
The trickiest part would have been imposible without her help.
She controlled the depth of cut on the pillar drill while I moved the sump around under the router bit.
Other help and moral support was also appreciated.
nicely done, good example of thinking outside the box.