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#61
Haus of Projects / Re: Yamaha YA-1 Resurrection
Last post by Yamanatic - October 26, 2025, 06:46:03 PMGasket time! I am sure many here probably already do it this way, but just in case it has never come up...
Smaller gaskets are easy; make a tracing and get out the Exacto knife and hole punch, and go to it. But if a big gasket (like a clutch cover) is needed, it can be a real pain to get right. OTC gasket material comes in a roll, which makes no sense because gaskets are flat. Here's a method that usually works first try:
To start, the gasket material is flattened (sort of) using a hot-water soak then laid out on a piece of board with the side-cover on top. Next, several drywall-type screws are ran into the board through the cover's bolt-holes, and tightened down to hold the gasket material firmly sandwiched between the cover and board. Then using a box cutter (my preference), cut around the OD giving the exact shape that looks pro on the edge that will show after installation.
For screw holes (which can be quite deep), a long 6mm drill bit is used, with the angle on the cutting ramps reduced to about 10-degrees to stop he bit from grabbing and tearing the gasket; this minimal angle on the bit is also used for drilling screw holes in plexiglass windscreens without causing stress-cracks or spidering. There was only one hole in the YA-1 gasket, but that's rare. The cover is now un-screwed from the board (by now the gasket has mostly flattened) and the ID is cut.
A pencil-compass (like those is used to draw drafting circles) is set to the width of the gasket face, and ran around the entire OD to mark the inner margin and give a point of reference. For screw bosses the 'dirty-finger' method works well; with the cover pointing up and the gasket blank held in position with the case screws, press very firmly around the inside curves of the boss edges and your fingers will leave a 'dirt' mark to trace around with the knife. To cut the ID, the box-knife was used except for the Exacto knife for tight curves - curved drafting protractors make excellent cutting guides. And that's it!
Next, the cover gets a trip to the wet-slurry blaster to erase the battery-acid etched cover (wet leaves a very original finish), and the kicker and shifter get re-plated. The pure (99.44%) zinc anodes arrive in a few days for the home electroplating process on the levers. Nickel is too 'gold,' and does not look like the bright cadmium used in the day - zinc is almost cad-white when polished.
Warren
Smaller gaskets are easy; make a tracing and get out the Exacto knife and hole punch, and go to it. But if a big gasket (like a clutch cover) is needed, it can be a real pain to get right. OTC gasket material comes in a roll, which makes no sense because gaskets are flat. Here's a method that usually works first try:
To start, the gasket material is flattened (sort of) using a hot-water soak then laid out on a piece of board with the side-cover on top. Next, several drywall-type screws are ran into the board through the cover's bolt-holes, and tightened down to hold the gasket material firmly sandwiched between the cover and board. Then using a box cutter (my preference), cut around the OD giving the exact shape that looks pro on the edge that will show after installation.
For screw holes (which can be quite deep), a long 6mm drill bit is used, with the angle on the cutting ramps reduced to about 10-degrees to stop he bit from grabbing and tearing the gasket; this minimal angle on the bit is also used for drilling screw holes in plexiglass windscreens without causing stress-cracks or spidering. There was only one hole in the YA-1 gasket, but that's rare. The cover is now un-screwed from the board (by now the gasket has mostly flattened) and the ID is cut.
A pencil-compass (like those is used to draw drafting circles) is set to the width of the gasket face, and ran around the entire OD to mark the inner margin and give a point of reference. For screw bosses the 'dirty-finger' method works well; with the cover pointing up and the gasket blank held in position with the case screws, press very firmly around the inside curves of the boss edges and your fingers will leave a 'dirt' mark to trace around with the knife. To cut the ID, the box-knife was used except for the Exacto knife for tight curves - curved drafting protractors make excellent cutting guides. And that's it!
Next, the cover gets a trip to the wet-slurry blaster to erase the battery-acid etched cover (wet leaves a very original finish), and the kicker and shifter get re-plated. The pure (99.44%) zinc anodes arrive in a few days for the home electroplating process on the levers. Nickel is too 'gold,' and does not look like the bright cadmium used in the day - zinc is almost cad-white when polished.
Warren
#62
General Chatter / Re: DG anodizing
Last post by m in sc - October 26, 2025, 05:39:57 PMdont powder coat, will keep heat in. get em anodized or cerakoted. No idea on a vendor
#63
General Chatter / DG anodizing
Last post by triple1972 - October 26, 2025, 05:12:14 PMHi guys. Have a set of DG400 perf heads that were cut and o ringed by Scott Clough. They are fine but thought I would have them re-anodized. Or is powder coating the way now? Any vendor reccomendations. I am in NH but might have to send them out of state. Help me !
#64
Haus of Projects / Re: Gray Ghost 421
Last post by Kawtriplefreak - October 25, 2025, 11:28:46 PM
Updated ETA 29 OCT.
And now they are saying 30 OCT
#65
Haus of Projects / Re: Gray Ghost 421
Last post by Kawtriplefreak - October 25, 2025, 02:54:23 PMThanks !!!
#66
Turning Wrenches / Re: Looking for opinions on pi...
Last post by quocle603 - October 25, 2025, 02:52:13 PMHeyyyyy. Its the little things that leads into big victories. Definitely something that could happen to anyone. Thanks for reporting back and updating the community
#67
Turning Wrenches / Re: Looking for opinions on pi...
Last post by ampzip - October 25, 2025, 10:17:59 AMThanks for the replies, got it exactly right. The bike starts perfect, idles perfect, runs perfect... been riding it a ton the last couple days, so satisfying.
#68
Haus of Projects / Re: Gray Ghost 421
Last post by m in sc - October 25, 2025, 08:16:47 AMlooking good 
#69
Haus of Projects / Re: Gray Ghost 421
Last post by Kawtriplefreak - October 24, 2025, 11:58:18 PMI am one hose and a set of pipes away from being ready to load the Gray Ghost on the trailer for the trip to the House of Haase for him to work his magic setting up the Zeel for the 421, jetting the PWK35s and other assorted shenanigans and mayhem. Lo and behold Wicked Motorsports shipped the pipes today via 3 day select UPS. ETA 27 OCT.
#70
Haus of Projects / Re: Gray Ghost 421
Last post by Kawtriplefreak - October 24, 2025, 11:46:40 PM
1.5 quarts of Walmarts finest type F ATF in the transmission for initial run-up. The coolant hose that runs from the top of the radiator to the fitting on the head is too short because it was trimmed to fit the previous iteration RZ motor with a thermostat housing.Further research revealed my Amazon radiator purchased a couple years ago is in fact a GPI Racing over-size radiator with an advertised 40% increase in cooiing capacity.
John st Economy Cycle to the rescue again for the win with a set of new hoses. Thanks John!