building a clear clutch cover

[Trueblood]

so, i decided to go for it. i have an extra clutch cover for my 750 kat motor and decided to try my hand at building a clear cover for the bike.

so first I used a 5 in bi-metal hole saw to cut the window out of the cover


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then i stuck it back on to see what it would look like (couldnt resist)
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cut out the lexan ( hard to do since you cant use a hole saw)
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so now we have to deal with the inside so we can mount the window, i used a dremel and cut off wheels to cut the "tabs" off and grind smooth.
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then here is a prefit of the window (its blue cause the protective film is still on it)
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now i drill and tap holes for bolts ( for decoration purposes)

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[Trueblood]

so then i use the dremel to cut the bolts off and grind smooth from the inside

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here are the bolts after they are cut.

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and the almost finished product.
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now i have not attached the window yet because i want to paint the cover first. as well as the bolts.

but when i do attach i will jb weld the window from the inside. i will also use rtv to seal any holes so the oil wont spill out.

unfortunately it will be a while before i get to test it cause its going in my fighter project.

[cintidude04]

looking cool

[yngveny]

Looking sweet, nice job

So the bolts are just for looks, not actually holding the "window" in place?

[Trueblood]

Looking sweet, nice job

So the bolts are just for looks, not actually holding the "window" in place?

yea i would have bolted it on if i built a ring and mounted the window from the outside. but hopefully this works and stays sealed. only time will tell

[il_ragazzo]

bolt clearances may prevent that from working though...

yea i would have bolted it on if i built a ring and mounted the window from the outside. but hopefully this works and stays sealed. only time will tell

cause the clutch windo might be very close to moving parts

[hardlydangerous]

do not use RTV use threebond 1211 or 1194

I have made several and have never had a great seal unless I used an Oring to seal them up or make a gasket, and seal both sides of the gasket. even then you need to bolt the glass in. JBweld wont hold up to the extreme heat and vibrations very well

[jetmerritt]

Cool idea!

[Black_peter]

interesting to see, what is the window made of?

[arsenic]

that's a novel ider

[1FSTKAT]

I was actually thinking of this today right before I saw this thread. Good job mate!

[Trueblood]

the window is 1/4 in lexan, the lexan will not stain (it may after a while but lexan is more resistant than regular plexi) from the oil and it does not have to be that thinck because there is really no case pressure on the clutch side.

do not use RTV use threebond 1211 or 1194

I have made several and have never had a great seal unless I used an Oring to seal them up or make a gasket, and seal both sides of the gasket. even then you need to bolt the glass in. JBweld wont hold up to the extreme heat and vibrations very well

thankx for the info bro. did you use nuts on the back of the bolt or did you just tap threads into the case and glass and use locktite

[hardlydangerous]

I think mine was 3/8" plexi ... I counter sunk flange nuts into the plastic and spread my bolts about 2" apart. Once I had it all set up I used a black gasket paper from Napa and a bit of 1194 on each surface before putting it together.
My first one I still had oil weeping around the bottom, so I had to tear it apart, clean it then re-sealed it a second time but this time I used sealant on each bolt and then used an epoxy to seal around the edges and the nuts.

My second one I made it fit on the outside... that was so much easier to seal up and no clearance issues using nuts

BTW remove the pressure plate and polish it.... it looks sick and oil wont stick to it

[Trueblood]

I think mine was 3/8" plexi ... I counter sunk flange nuts into the plastic and spread my bolts about 2" apart. Once I had it all set up I used a black gasket paper from Napa and a bit of 1194 on each surface before putting it together.
My first one I still had oil weeping around the bottom, so I had to tear it apart, clean it then re-sealed it a second time but this time I used sealant on each bolt and then used an epoxy to seal around the edges and the nuts.

My second one I made it fit on the outside... that was so much easier to seal up and no clearance issues using nuts

BTW remove the pressure plate and polish it.... it looks sick and oil wont stick to it

thankx man, i atcually have been doing some research and i am going to take the plate to be powder coated to match the accent color of the bike. the guys over on the fighter forum have done this with good results. but polishing sounds awesome too. do you need to keep polishing it?

[hardlydangerous]

no once its polished it will stay nice for years