Final drive vent cap repair

[John]

The XS850 final drive that I just bought is missing the cap on the vent. I did a search for a repair tip, but no luck. I know I've seen it discussed in here somewhere, but could find it. Has anybody found a way to replace the cap? I have an old FD that I can remove the cap from. but I'd rather pick someone's brain, before I butcher something up needlessly.

[randy]

John,

I replaced my vent last year (thanks, gary) and it was a bitch to get out, wound up chewing the old one up with vise-grips and torch heat. New one went in easy, though, left it in the freezer overnight.

[xschop]

cap repair

I just used a stainless steel cap with high temp silicone allowing for air passage. never had a problem. Used a Wal-mart/chinese made measuring cup polished to chrome....chop

[John]

Randy

How did Gary get the replacement vent out of the donor FD without damaging it? Do you know?

[randy]

Gary66 didn't get it from a donor - he gave me an NOS part!

What I first attempted was a small (like needle nose) vise-grip under the lip, tried to knock it out, but the cap broke off the shaft so I wound up 'chewing' on it 'till I rotated it out. Heat helped.

[MAXIMAN]

Chop

All I can say is "XSellent"!

[John]

I think I have a fix for it.

When I was at the hardware store buying the 3/4 inch copper connector/bushing I need for the final drive swap that I'm doing, I saw a 3/4 inch copper pipe cap that resembled the vent cap. My idea is to use a 1/4x1 inch bolt and drill down the length of it, and then cross drill it below the head, like a bajo bolt in the brake system. I plan on removing the threads on the bolt, making it smooth. Then I will drill the hole in the broken vent to accept the smoothed bolt, and JB Weld it into place. After that I will epoxy the cap to the bolt head, and Viola!
Looks real good on paper, any way.
I finished the prep work on the new final drive today at work (thanks AA), and I with the forcast calling for rain the next few days, I will be doing the swap over soon.

[John]

It's fixed

I had an old FD laying around, so I just used a die grinder with a cutoff wheel, and sliced the aluminum away from the front of the vent. Came right out then. I stuck the new vent in the freezer for a while. I removed the old one by running a sheet metal screw in the hole, clamped onto the screw with a vise grip, and struck the vise grip lightly with a hammer, and it came right out. New one slipped right in with a few light taps with the hammer. The mods are completed, and the FD is ready for paint. That will happen today, and I'll start the swap over tonight or tomorrow. I really want to watch the New England-Indianapolis game tonight though. GO PATS!