Gasket manufacture .....

[ukjules]

Must be bored as I am actually going to ask this
question.

Sick of breaking and wasting time with small
gaskets like cam chain tensioner one .
Thus out from the parts mountain in garage
I find my old gasket papers.

Q) how other than using a drill bit can you
gouge out a perfect circle too big for most drills ...

20201118_211848_resize_98.jpg

[ukjules]

Aha on ebay can get a hollow punch up to 19mm
HOLLOW PUNCH SET 3mm-19mm Round Circle Leather Hole Gasket Cutter

for 10£.

[Nessism]

Sharpen a piece of tube and use it as a punch works.

[Gorminrider]

Yes...some of the punch sets are low grade chinesium and don't hold an edge any better than a piece of aluminum tube! or they are too brittle.... a really good punch is really the same as a really good chisel in steel and temper and dear to buy $$$

BUT whichever, to preserve the sharpness, it might be a tip for you to use a block of wood's END GRAIN underneath the gasket you are punching...("end grain" is where you can see the wood's growth rings)

[ukjules]

My first thought on such things is the
"Flight of the Phoenix " scenario where
I have to do this, but dont have any aluminium
tubing at hand . but can still use my mobile
to contact the GS resources forum.
[flight of the Phoenix being a film where they had
to use what they had in the desert to build
a plane out of a crashed plane ...]
The above being similar to being poor.

But I agree there is no way bar hacking at it
with scissors and a drill which can only be
used in an emergency.

I started to think could I use the sun and
a magnifying glass to burn a hole but then
realised it doesnt matter ....

[Agemax]

a sharp knife and a steady hand makes for a pretty good hole cutter

[Steve]

Even if it IS made of Chinesium, if you can get a set for 10£, do it.

.

[hampshirehog]

Gently tap it out using a ball pein hammer.

[tatu]

I started to think could I use the sun and
a magnifying glass to burn a hole but then
realised it doesnt matter ....

There's sun in UK? Just how big is this magnifying glass?

You could press the gasket material against the place where you want the gasket out and tap it out like Wally says or just press it hard so that the paper is imprinted and cut it with a steady hand like Adrian says.
A little gasket like the cam chain tensioner I'd be tempted to draw round with a sharp pencil and cut it out.
Those titchy gaskets are expensive for what they are also a smear of your 3 bond

[fastbysuzuki]

Do not cut the required shape out first and then punch the holes as this almost always results in the punched hole splitting though and spoiling the gasket.
Draw or trace the gasket required but not to close to the edge of the gasket paper then punch the holes and then cut out the shape.
For cutting larger holes something like this may be usefull https://www.amazon.co.uk/Olfa-Compas...97438318&psc=1

[John Park]

[QUOTE=fastbysuzuki;2631385]Do not cut the required shape out first and then punch the holes as this almost always results in the punched hole splitting though and spoiling the gasket.
Draw or trace the gasket required but not to close to the edge of the gasket paper then punch the holes and then cut out the shape.

This was apprentice work, back when we had apprentices. The trick is to have a small enough diameter ball peen with some weight to it. The partially punched out holes will also hold the paper to the piece while you turn it over and trace the outline or while you continue peening out the gasket with the hammer. I remember well the first time I made one maybe fifty years ago under the tutelage of an English guy.

I also find that having nail scissors in both straight and curved are handy for snipping out the last of the holes and doing the outline. You don't have to go all the way through the material but leave enough here and there for stability while you work.

And Fastby, your signature may be the only place ever where Hayabusa and Francis Barnett are ever used in sequence. A Frannie B lived in my garage and, due to the folly of youth, I never had the presence of mind to put it back in service. It probably ran; I never bothered to find out.

[fastbysuzuki]

[QUOTE=John Park;2631389]

This was apprentice work, back when we had apprentices.

Yes I was one of those lads, started my apprenticeship at Mather + Platt at the age of 16 that was 58 years ago as for the Francis Barnett that was a 197cc flying falcon my very first motorcycle in British racing green ( could you get any other colour) lol
well one thing is for sure I bet we both wish we still had the bikes in our garage we'll I do anyway.

[GregT]

If I have to make a gasket from gasket paper now, I clean off the cover surface - even rub it on a sandpaper covered flat surface - then coat it with contact adhesive.

Lay the cover - glue down - on your paper and weight or clamp it in place.

When set go round it inside and out with a sharp blade.

I've got engines here I've made them for this way and they've lasted years. The covers come off cleanly with the gasket attatched. Reuse until totally stuffed.

And I've got a 197 Villiers roadrace special here. Engine has 6E cases - and a 4 speed Greeves box. Faster than 250 Ducatis.

[John Park]

Greg, that sounds like a better way to do it with thicker papers. I'll have to try it out. THX

[ukjules]

All good reading .
Gasket paper marked out and not cut out or holes punched
in readiness for major 10£ purchase of gasket hole punch set.

(I am lucky as kept the first bike i ever bought
(not new), a 1977 RD250D) You return to being 16
when setting off on it !