Starting on the Generator Cover

Back to making chips!  This post is the first part of fabricating the generator side engine cover.  this is a 2 piece cover with a threaded inspection port to give access to the end of the crankshaft.

I'm doing the same process as used with many other parts: first machine the inside surfaces from a billet of aluminum, then in a following post I'll machine a fixture plate that locates to these features and then machine the external surfaces of the part.

The internal features and mounting holes are critical to the correct placement of the stationary stator with respect to the crankshaft mounted rotor.  By machining these in one setup I am assuring high accuracy between these features.

Skipping directly to the chase (I forgot to photo intermediate machining steps!)  Here's 3 sets of parts:  3 completed access ports and 3 1/2 machined side covers.

Threaded inspection port:

This was a 3 operation part: first turn the thread, counterbore and o-ring sealing groove, then turn around and turn the outer profile, then switch to the mill to make the 17mm hex for wrenching.

Generator side cover at the halfway mark:

This operation created the outer profile, mounting and locating holes, and mounting holes for the Electrx race stator.  This product from Electrex is a low profile race generator kit meant to replace the larger systems found on production Japanese motorcycles at about 1/5 the cost of a similar race kit item from any of the manufacturers.  Build quality was excellent and they are great source for low volume OEM sourcing of generator components.

Here's the stator bolted in place with the 3 phase wiring exiting though a slot in the gasket surface:

Next up is capping the ends of the valve covers and then final machining of the welded cylinder heads and valve covers.

Until next time.