BMW K bikes (Bricks)

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151Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon Apr 13, 2015 5:19 am

Ed


Life time member
Life time member
too many sidewinders Waz, bet you've been having fun though.
did the bike roll to a smooth halt? could it be anything in the final drive gearing , maybe not holding up for you , just a thought.
start your inspection from the rear and work your way forward. Lift the rear off the ground and rotate the wheel , you may feel something grinding from back there, that may give a sign of where the damage is.

    

152Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon Apr 13, 2015 9:22 am

Waz

Waz
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Rolled to a smooth but noisy stop. Hope it's the final drive because I have a spare but I rekon it's the shaft. Have a few other jobs to do on RS before I start on it.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

153Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Thu Apr 16, 2015 2:24 am

charlie99

charlie99
VIP
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bugga

hope it is an easy fix waz

cheers


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%OTransformed again - Page 4 Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

154Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Fri Apr 17, 2015 9:55 pm

Waz

Waz
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Looks easy enough uni joint failed, will have to remove the swing arm to get the rest out.
Transformed again - Page 4 100_0812
Need a new shaft
Transformed again - Page 4 100_0813


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

155Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sat Apr 18, 2015 12:21 am

Ed

Ed
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Life time member
hmmm .... be interesting to see what the other end of the shaft looks like.what is still rotating at this stage?


__________________________________________________
1993 K1100RS  0194321         Colour #690 Silk Blue  aka " Smurfette"
2018 Kart upgrade.
Transformed again - Page 4 10_x_110
    

156Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 4:26 am

Waz

Waz
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The universal joint from the drive shaft is still attached to the out put shaft of the gearbox and is still rotating.
Got another drive shaft and fitted a new universal joint with a grease nipple and welded a new spline in the other end.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

157Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 4:47 am

charlie99

charlie99
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VIP
really ...?

got pics waz ?..... never seen it done before

details please


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%OTransformed again - Page 4 Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

158Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 5:23 am

RicK G

RicK G
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I would like some details on the uni joint and how it is retained please.


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki
    

159Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 5:45 am

smithy

smithy
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Life time member
I got a rebuilt driveshaft of Rockman a good while ago now, I think it was in his adventure sidecar once.
It had new splines welded in and a new universal joint fitted, the uni is retained by spot welds. I did a similar thing with the universals on the driveshaft's of my Suzuki king quad about 10 years ago and it's still going strong.


__________________________________________________
87 K100rs : Vin 9462 
86 K100rt : Vin 9901
Naked
98 K1100lt: Vin 8044
    

160Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 6:06 am

Waz

Waz
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The grease nipple that came with it was no good, too large I replaced this one with a smaller straight one.
Transformed again - Page 4 Img_0410
After measuring, cut the worn splines off.
Transformed again - Page 4 Img_0411
The new splines slip inside the drive shaft, the new piece has a 45deg edge so I ground the drive shaft edge to 45v deg as well leaving a nice V shape to fill with weld.
Transformed again - Page 4 Img_0412
Transformed again - Page 4 Img_0413

Transformed again - Page 4 Img_0414
Then ground it smooth
Transformed again - Page 4 Img_0415

Transformed again - Page 4 Img_0417

easy peasy


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

161Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 6:11 am

Waz

Waz
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Life time member
I would like some details on the uni joint and how it is retained please

It come from Munich motorcycles WA
It was just a compression fit. Took some force and a large vise.

Gaz suggested tack welding the caps on the uni but I haven't yet, maybe I should after seeing your comments Craig



Last edited by Waz on Sun May 03, 2015 6:20 am; edited 1 time in total


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

162Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 6:16 am

smithy

smithy
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Life time member
Good job Waz, well done


__________________________________________________
87 K100rs : Vin 9462 
86 K100rt : Vin 9901
Naked
98 K1100lt: Vin 8044
    

163Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 6:41 am

Ed

Ed
Life time member
Life time member
excellent work there Waz. Be good to see you back on the road again.


__________________________________________________
1993 K1100RS  0194321         Colour #690 Silk Blue  aka " Smurfette"
2018 Kart upgrade.
Transformed again - Page 4 10_x_110
    

164Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 6:55 am

charlie99

charlie99
VIP
VIP
@Waz wrote:I would like some details on the uni joint and how it is retained please

It come from Munich motorcycles WA
It was just a compression fit. Took some force and a large vise.

Gaz suggested tack welding the caps on the uni but I haven't yet, maybe I should after seeing your comments Craig

usually the caps of the uni joint are peened over with metal from the surrounding housing

seems to work

Transformed again - Page 4 20150510


thanks for the pics mate ...made a lot of questions ....solved

just an observation  ,,, id really like to know how you intend to get to the grease nipple once assembled....giggles
but I guess you could pressure it up before fitting... to confirm good grease has made it to the roller bearings  ... I guess with  a very slim adaptor it could be done through the input spline ....good thinking was




good luck



Last edited by charlie99 on Sun May 03, 2015 7:07 am; edited 2 times in total


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%OTransformed again - Page 4 Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

165Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 7:02 am

smithy

smithy
Life time member
Life time member
Yes the preened over metal tabs can still be done again, but with spot welds it wont go anywhere and if you need to change the uni again in the future it's much easier to grind the spot welds off.


__________________________________________________
87 K100rs : Vin 9462 
86 K100rt : Vin 9901
Naked
98 K1100lt: Vin 8044
    

166Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 7:05 am

Mark K Boy

Mark K Boy
Gold member
Gold member
@RicK G wrote:OoooHHoo worst case of K-pox I have ever seen.

Do you think you can save him doctor or has it gone too far?

I'm with you mate she has to be bent.......


__________________________________________________
Mark Surman
Keep the shinny side up !

Transformed again - Page 4 Au-log12
http://www.marksurman.com
    

167Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 03, 2015 7:22 am

Waz

Waz
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Life time member
id really like to know how you intend to get to the grease nipple once assembled....giggles
Yeah can only get to it after removing the drive shaft but can do it when I am greasing the splines.
Transformed again - Page 4 Img_0418
My little grease gun fits
Transformed again - Page 4 Img_0419

I will tack weld the caps just to be safe, the originals where tough to get out very tight fit.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

168Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon May 04, 2015 5:44 pm

sidecar paul

sidecar paul
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Life time member
That's a good job Waz.  Transformed again - Page 4 112350

It would be worth repeating the pictures and detail in the 'How To' section, so that we can find it easier in the future.

Paul.


__________________________________________________
'84 K100RS (0014643) (owned since '85), 86 K100RS (0018891) with Martello sidecar (built as an outfit in '88),
'51 Vincent (since '67),'72 Montesa Cota (from new), '87 Honda RS125R NF4 (bought 2015) 
....No CARS never ever!
    

169Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon May 18, 2015 8:57 am

Waz

Waz
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Thanks I will do that.
Removed the swing arm to get remainder of uni joint out.
Transformed again - Page 4 Uni10



Tack welded the caps and bolted it all back together today.
Transformed again - Page 4 Img_0510

Replaced the final drive too it was growling. Back on the road.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

170Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon May 18, 2015 12:48 pm

Holister

Holister
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Life time member
Thanks Was. Interesting read. Glad to see you got it sorted.
Can the uni-joint be regreased without the grease nipple?


__________________________________________________

1989 K100RT     VIN  0097367 (naked)  
1996 K1100RS   VIN  0451808
  Transformed again - Page 4 Austra12    Fuel:  95 Octane
Engine Oil: Nulon Full Synthetic 15W50
Gear Box Oil:  Nulon Synthetic 75W90
    

171Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon May 18, 2015 8:17 pm

Waz

Waz
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Life time member
I don't think so.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

172Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 24, 2015 7:30 am

Waz

Waz
Life time member
Life time member

  1. Just get the dog to sit in the sidecar while you're fiddling about nearby, give him his bedding and maybe some treats.  make it a nice place to be.

  2. Start the engine and let it run, dont ride it you're just trying to get him used to the noise.

  3. Short rides first maybe go to a favourite place, visit another dog friend, go to the park or the creek or something.  Try to make him associate a ride in the sidecar with a good experience.

  4. Then work on building more confidence.  Make sure you give him a break regularly, it's good for stretching your legs too.



Getting there, steps 1 and 2 completed he was jumping out as soon as I hit the starter but now will stay until I put it in gear then he launches out.

Transformed again - Page 4 Img_0213


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

173Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 24, 2015 7:49 am

Stan

Stan
Life time member
Life time member
Place a photo of a cat on windscreen of side car and tell him to focus.


__________________________________________________
1983 K100 basic vin 0003960 colour red  GONE
1987 K100RT vin 0094685 colour, orange peel, sorry, pearl..GONE
F800R black
    

174Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon May 25, 2015 6:13 am

AL-58

AL-58
Life time member
Life time member
@smithy wrote:Yes the preened over metal tabs can still be done again, but with spot welds it wont go anywhere and if you need to change the uni again in the future it's much easier to grind the spot welds off.
The way I've heard some do it is to place correct sized flat washers over the end caps and weld to the washers.  Doesnt put so much heat into the caps and rollers inside.

Al


__________________________________________________
'87 K100RS/HRD sidecar (1100 motor)  sc25 
'92 K100RS-16v (Paint it Black)

'87 K100RT with Paralever backend

"When I'm too old and too foolish to handle a sidecar I'll buy a Sportsbike"

Transformed again - Page 4 K-dogs10
    

175Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Jun 03, 2015 6:34 am

gabriel

avatar
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Just had a thought....adding a sidecar to a BMW....how much additional weight would that be...consider that the bike and the standard driveshaft has to deal with a lot more weight?
The driveshaft is only as strong as its weakest point which I consider to be the uni joint..
Those cement bags wouldn't have helped?
I'm no expert......compare the driveshaft on a truck compared to a car....
The"twisting" forces on that driveshaft trying to move forward when the total weight of the bike is doubled......just a thought...
Any opinions...
BMW has a policy of discouraging owners from adding a sidecar...how many of us know they technical limitations of the standard driveshaft whe adding extra weight to a bike...
The k100 has a maximum weight limit...for a reason...adding a sidecar doubles, triples that weight limit?

    

176Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Jun 03, 2015 5:51 pm

sidecar paul

sidecar paul
Life time member
Life time member
No problem with a well lubricated driveshaft gabriel,

I had a uni joint fail on the outfit in the early '90s, with about 25,000 miles on the clock. I bought a new shaft and a spare, in case it happened again, but the spare is still in it's BMW waxed paper wrapping and the replaced shaft still looks as good as new after 112,000 miles. cheers 

Paul.


__________________________________________________
'84 K100RS (0014643) (owned since '85), 86 K100RS (0018891) with Martello sidecar (built as an outfit in '88),
'51 Vincent (since '67),'72 Montesa Cota (from new), '87 Honda RS125R NF4 (bought 2015) 
....No CARS never ever!
    

177Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sat Jun 13, 2015 7:10 am

Waz

Waz
Life time member
Life time member
That's a good job Waz.


Not really, I did NOT tighten the rear wheel properly and it transformed into a two wheeler again.
Transformed again - Page 4 Photo13

But it was going very well before this happened. I fitted a new rear shock and that fixed the poor handling.

I have just ordered a new rear disc. Should be ready for the NSW BMW touring club new members BBQ at Mt Wilson 28th June. Hoping to get to the BBQ and back without a tilt tray or trailer.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

178Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sat Jun 13, 2015 7:08 pm

Stan

Stan
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Life time member
Maybe be a hidden message here...motorbikes have two wheels. :cyclops:


__________________________________________________
1983 K100 basic vin 0003960 colour red  GONE
1987 K100RT vin 0094685 colour, orange peel, sorry, pearl..GONE
F800R black
    

179Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Jul 01, 2015 4:01 am

Waz

Waz
Life time member
Life time member
Has anyone one had to use helicoils? are they strong enough to hold the back wheel on?


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

180Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Jul 01, 2015 4:37 am

RicK G

RicK G
VIP
VIP
Yes they used to hold my nitro engines together. Not sayin that they never left a big pile of crap under then from time to time but none of the helicoils ever let go.


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki
    

181Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Jul 01, 2015 4:52 am

Waz

Waz
Life time member
Life time member
Thanks Rick, I will have a go.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

182Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Jul 01, 2015 5:21 am

Gaz

Gaz
Life time member
Life time member
I've used small ones a few times Waz on covers etc. and was surprised at how easy it was to fit them. Nothing as serious as Rick has used them for but having his feedback I'd say go for it!

Cheers


__________________________________________________
Gaz
1990 K75 6427509; 1987 R80G/S PD 6292136; 2010 G650GS ZW13381; 95 K1100LT 0232224
    

183Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Tue Aug 04, 2015 2:28 am

Waz

Waz
Life time member
Life time member
I will carry the final drive with helicoils as a spare, I had a spare 16 tooth final drive and have fitted it with a new rear disc. Been out testing and all is good again but handle bars are now bent. I must have been hanging on too tight.affraid


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

184Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Tue Aug 04, 2015 2:56 am

Gaz

Gaz
Life time member
Life time member
I thought you might also need to have the seat recovered to remove the pucker creases out of it.

Cheers


__________________________________________________
Gaz
1990 K75 6427509; 1987 R80G/S PD 6292136; 2010 G650GS ZW13381; 95 K1100LT 0232224
    

185Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Tue Aug 04, 2015 5:48 am

AL-58

AL-58
Life time member
Life time member
I can help with the seat recovering if need be Wink

Good to it will be back on the road again.

Al


__________________________________________________
'87 K100RS/HRD sidecar (1100 motor)  sc25 
'92 K100RS-16v (Paint it Black)

'87 K100RT with Paralever backend

"When I'm too old and too foolish to handle a sidecar I'll buy a Sportsbike"

Transformed again - Page 4 K-dogs10
    

186Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Aug 05, 2015 1:36 am

Waz

Waz
Life time member
Life time member
I did have a firm grip on the seat but it's ok


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

187Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Thu Aug 06, 2015 10:52 pm

Two Wheels Better

Two Wheels Better
Moderator
Moderator
@Waz wrote:Has anyone one had to use helicoils? are they strong enough to hold the back wheel on?
I was once having a sook when the mechanic at the workshop where I worked was suggesting Helicoils in the slightly stripped sparkie holes of my '77 Airhead. He just looked at me sideways and asked if I'd ever seen an aluminium helicopter chassis. He'd been a chopper repairman in Vietnam. I said no. He replied that every single steel fastener went into a Helicoil or time-sert. The Helicoils are still in my Airhead cylinder heads nine years later.


__________________________________________________

Sometimes I lie awake at night, and I ask, "What can I do to keep my life from going by so fast?" Then a voice comes to me that says, "Try slowing down at the corners." 

~Charlie Brown

1970 R60/5, '77 R75/7-R100, '85 K100'87 K75C, '87 K100RS, '93 K11-K12 Big Block, '93 K1100RS, '95 R100-Mystic, '96 K1100RS, '98 K1200RS, '00 K1200RS, '02 K1200RS, '03 K1200GT, '04 R1150R'04 R1150RT, '05 K1200S, '06 K1200R, '07 K1200R, '09 K1300GT & 2013 R1200RT-Polizei  - Beemers owned still or sold.

    

188Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 22, 2016 5:41 am

Waz

Waz
Life time member
Life time member
I was very close to pulling it apart and making a bike out of it.
I have been having squirming handling problems since the loose wheel ordeal. I have reduced the overall width, stiffened rear suspension, replaced sidecar torsion suspension, replaced connecting bars (bent) and replaced all connecting nuts and bolts. But still unpredictable wandering on rough or uneven roads, I was getting nowhere until Saxon give me some tips and got me on the right track. Now it's very close and I can ride or drive it again. Only needs some minor adjustments now.

Big thanks Seanii firstly for getting me motivated again and secondly getting me on the right track.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

189Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Sun May 22, 2016 7:05 am

charlie99

charlie99
VIP
VIP
great to hear Waz

keep at it mate ..

good luck


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%OTransformed again - Page 4 Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

190Back to top Go down   Transformed again - Page 4 Empty Transformed again on Sun May 22, 2016 8:13 pm

RT

RT
Life time member
Life time member
Oh Waz, such a short memory.
I'll look out for some brown undies for you.


__________________________________________________
2011 R1200RT
    

191Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon May 23, 2016 7:06 am

Ed

Ed
Life time member
Life time member
good to hear you're moving in the right direction Waz . Cheers.


__________________________________________________
1993 K1100RS  0194321         Colour #690 Silk Blue  aka " Smurfette"
2018 Kart upgrade.
Transformed again - Page 4 10_x_110
    

192Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Mon Oct 10, 2016 6:56 pm

Waz

Waz
Life time member
Life time member
My new steering head bearings where also chewed out. Didn't think to check them because they were new. Another set of bearings has made a huge improvement. It may make an appearance at Philip Island next week if I can find brown undies for the trip. Still feels like it is 90%. Every time I get an improvement I think now it's 90%. Now it will cruise at 110 without wandering.


__________________________________________________
1988 K100 RS
1999 K1200 RS
1987 K100RS DJP sidecar
    

193Back to top Go down   Transformed again - Page 4 Empty Re: Transformed again on Wed Oct 12, 2016 11:40 am

rawdonball

rawdonball
Platinum member
Platinum member
Hi Waz - I've enjoyed reading the last 40 odd posts in this thread, not sure how I missed it previously. Some good stuff here - I like the idea of being able to re grease the drive shaft uj for instance...
A project I dream about every now and then, is the idea of one day finding a small CV joint off a drive shaft from a front wheel drive vehicle that I can use to 'upgrade" one of my K75 bikes! Has anyone heard of this being done anywhere? It would surely ease the duty on the final drive splines to my mind.

By the way - I'm with TWB as regards helicoil equipped fasteners often being more reliable than those in standard tapped bores. As long as the larger drilling in the unit doesn't compromise the integrity of the original item as could be the case in aluminium castings not specifically designed with helicoils in mind as was obviously the case in the helicopter story. For steel bolts in light alloy castings the female thread is the critical one and the increased bore diameter when fitting a helicoil means the area of the thread that is seeing the load is increased. This results in lower stress levels in the female bore thread for a given bolt load. The first helicoil I ever saw was in the rotor of a cropping machine designed to cut multiple one inch wide by 1/4 inch thick strips of pure nickel into squares. The fitter I was assigned to for the blade change task wasn't familiar with the spring insert concept so I HAD to grab the tail of this 'spring' with a pair of long nose pliers and pull this odd looking thing out - I wasn't in the Foreman's good books when I took him the extended helix of a steel snake to ask 'what now?' Foremen love an opportunity like that to ask learner Engineers - 'don't they teach you ANYTHING at that university". Anyway - those helicoils were per original design specification. Presumably due to it being a classic fatigue loading scenario - production machine doing 20+ hours a day in a refinery producing electrolytic grade nickel for manufacturers of turbine blades....


__________________________________________________
'88 K100RT, '86 K75C, '05 Yamaha TTR250
    

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