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Old 16-05-18, 08:50 PM   #1
Tamsen Cooper
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Default Clear clutch cover- home build

Hi All,

So with the spare engine I featured in one of the videos, I thought it would be cool to use the spare clutch cover I have to have a go at making a transparent clutch cover at home. Now I have read many, many threads, on this site and others about this process. The slight frustration is that many of the pictures are now broken links so I am following mostly words with some pictures online.

So here are my questions I have not encountered
  • I intend to use a drill to cut a series of drilled holes very close to each other to cut out the shape (mine is the plastic cover), is there much chance of the plastic cracking? Hoping to use a handsaw to cut out the detail and file (open to suggestions)
  • I have seen that lexan is suggested by many, of those that have had it for a few years, it is discoloured or is there a better material recently?
  • On the 2002 I have, the oil filler comes into the main centre, some have machined a whole new cover whilst others have made a much smaller hole for a viewing window, which would be a bit of a shame. Has anyone seen a version with a 'cut out' for the oil filler, so the main window is circular but with a small 'chunk' out of it- just wanted to see what it may look like!

Any other tips from people that have had a go/ seen it done?

Thanks as always
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Old 16-05-18, 09:10 PM   #2
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Default Re: Clear clutch cover- home build

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Originally Posted by Tamsen Cooper View Post
  • I intend to use a drill to cut a series of drilled holes very close to each other to cut out the shape (mine is the plastic cover), is there much chance of the plastic cracking? Hoping to use a handsaw to cut out the detail and file (open to suggestions)
I've no experience of making a clutch cover, but for something like that I think a hole saw would be a lot easier and neater. Should go through easy with it being plastic

https://www.screwfix.com/p/erbauer-b...00022861107919

https://www.screwfix.com/p/erbauer-1...32-152mm/1779h
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Old 16-05-18, 09:43 PM   #3
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Default Re: Clear clutch cover- home build

That is a good suggestion, I guess I would just have to take it slow but it would make a perfect circle!
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Old 16-05-18, 10:06 PM   #4
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Default Re: Clear clutch cover- home build

Iíve heard of people using the drill in reverse when cutting plastic with holesaws to prevent grabbing and subsequent damage.

YMMV

Would be interested to see the end result

Pete
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Old 17-05-18, 05:45 AM   #5
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Default Re: Clear clutch cover- home build

I'm wondering whether using some masking tape on the cover before you start the cut would help too?

Might help it to stop it splintering?

I don't have this problem, as I've got one of Nils CNC covers with a clear cover
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Old 17-05-18, 07:08 AM   #6
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Default Re: Clear clutch cover- home build

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I don't have this problem, as I've got one of Nils CNC covers with a clear cover
Iím not sure which one of the designs that is, would you mind posting a picture? (like I said, most thread pictures are now broken links) but I was struggling to see anyone selling one still, and thought it might be fun. I do have an adjustable circle cutter that attaches to a drill- does anyone know the depth of the plastic that makes up the cover?
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Old 17-05-18, 07:36 AM   #7
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Default Re: Clear clutch cover- home build

As above.Mark where you are going to drill and then place some masking tape or a couple of layers of cello-tape over the mark so you can still see it.This helps stop plastic splitting and I use this method when drilling into metal as it acts as a sacrificial guide for the drill bit to get it started and stop them skipping.

HTH
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Old 17-05-18, 10:33 PM   #8
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Default Re: Clear clutch cover- home build

I'm never one to dissuade someone from making something themselves. However...

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I was struggling to see anyone selling one still
Cyberdyne Clutch Cover Suzuki SV650

I can see the making of one being an interesting experience, but there will be challenges and you have to consider is the juice worth the squeeze.
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Old 18-05-18, 05:09 AM   #9
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Default Re: Clear clutch cover- home build

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Originally Posted by Tamsen Cooper View Post
I’m not sure which one of the designs that is, would you mind posting a picture?
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Last edited by maviczap; 18-05-18 at 05:11 AM.
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Old 18-05-18, 11:54 AM   #10
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Default Re: Clear clutch cover- home build

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That is stunning!! Is he still doing them do you know?
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