What a productive week for the bike! I was able to get some more time in on the mill and complete the machining of the clutch cover. The last operation on the part was machining the interior pockets, profile, and starter gear mounting features.
The next step is to make a fixture plate that can locate from these previously machined features then bolt the part to it and finish the outer surfaces.
First, I machined a plate with some dowel pins to accurately locate in the machine table t-slots:
Then I ran a second program that drilled a hole pattern to match the mounting and alignment holes of the part:
Holding it like this will allow me to run the first half of the program, pause it, reclamp the part using the perimeter mounting holes and remove the large fixture bolts, then resume the program and complete the part:
Repeat those steps and I ended up with 2 good parts:
Next part is the clutch cap that bolts to the outer large circular boss and contains the helical clutch release mechanism. Hopefully this week will have some time for me to get to it.
After bolting this part on I'm realizing that we're not too far from a complete engine! Wow. Time to knuckle down and make it happen ASAP.