justin_o_guy
Ex Member
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I took 4 or 5 pics before it came out clear. Doesnt matter. A 1/32 hole with a .025 wire thru it is too small to see unless yer holding it. I even used whiteout on the wire & a blue map pencil on the cast aluminum to try to get enough contrast to make it visible..
Anyway, heres a description:
I used a 1/32 end mill in a drill press & cut a small recess of about 65 thousandths deep by about 3/16ths long, running next to the slot the ratchet sits in.(Note:I really didnt sit down & think this thru, just walked off into it. I, as a result, had to get outta trouble & if I had thought about it first, I think I coulda done it better & easier.) After I got the recess made, so I could drill a hole & it not be on a radiused area, I realized I needed a very small hole & the smalles drill bit I have is 1/16th, so I looked ate the 1/32 end mill & even tho it is only about a 1/4 long before it tapers to a 1/4 shank, I really had nothing else, so I used that. Now, in order to make that work I tilted the body of the tensioner in the vise on the drill press( before any start thinking I have such a wunnermuss shop, I will tell you that the drill press was about 50 bucks off a "Eeverything made in China" truck & the vises, one travels 2 directions, so I can pretend I have a mill, were super cheap & work like crap, but I can make stuff happen, just takes much patience. )So, I used the mill tip to poke a hole at an angle into the far side of the tensioner & then , using the slide vise so the holes lined up, ealked the tensioner over & marked the side with the recess using the mill tip. Then I re set the tensioner in the vise so it would poke straight thru & drilled it on the mark. Now, all well & good except the wire is too high to catch the ratchet, so , after I drilled a hole in the corner of the tensioner( If ya look at the ratchet part, holding tensioner so the part that goes to the cam chain guide is pointed up, the area below it looks like a Y with the ratchet mounted in the arms of the Y, In the lower left corner, I drilled a hole to run the piano wire thru & bend it back on itself so it cant come out. Then I used a small punch to drilve the wire lower so as to trap the ratchet.. Voila! Took almost as long to type as to do it..
Built some clutch spring spacers from 3/8 washers, too. Stuck them on a bolt, ran them in the drill press & used a 4" grinder on them while they spun, then drilled them out. Hadda grind flat spots on them to keep them from spinning in the vise..
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