stuck float pin/ Float pin tool

[prometheus578]

"Where have I been...?"

Didn't notice that this post was reactivated.
Wet Rock... Ken's extractor works like a dream. Tore through three banks o' carbs like they were nuttin'.
Works great on the early models. The later models had square edged towers, so it didn't immediately fit, but a little filing in the corners of the tool's holes fixed that problem. Just wish I had more carbs to toy with. After years of fighting this problem... it's a breeze, now.

[Ken Talbot]

CNC Milling capacity

Hey, tmworks, I noticed in one of your recent posts that you have a CNC mill, and it looks like you can do some pretty fine looking work with it. Any chance you might be interested in taking on a little project?

[mro]

Hey Ken, this was 2 years ago
Whole new batch of XSives on board.
Are you thinking of making/having made another batch?


mro

[Ken Talbot]

This past summer, I tried making a few from a piece of aluminum channel stock I got from a local machine shop. Must have been a pretty low grade of aluminum, because the pieces just folded up on me. There was no way I could have tapped them for the screw, elongated the holes, etc. I know channel iron works, but doing them by hand is pretty time consuming. That's why I'm hoping that reviving the thread might dredge up someone with the "technology" to automate the process.

[Ken Talbot]

Prom - this is your lucky day!

Your PM the other day got me thinking about this project again. That, plus SWMBO is out of town for a meeting tonight, so I have some unsupervised time in the basement. I had another go at the aluminum I tried before, and I think I've come up with a design modification that will work. Here's what it looks like:



Send me another PM with your mailing address, and I'll send you this prototype for testing.

[prometheus578]

Oddly, or maybe not considering me..."

... I have the original "carb float post tool" sittin' rat-cheer in front o' me next to my monitor. I sit here for hours... turning it over in my fingers.. marvelling at your brilliance....
(Ok, it was in my pocket a few days ago and I was too lazy to put it back in the tool box in the garage)
I don't recall if I addressed this with the first batch.
Those rounded holes for the posts.
The earlier carbs.. their posts are more squarish.. the tool doesn't fit. Is it possable to either square off the corners, or would making the holes "longer' be easier?
Or.. I can just take a jeweller's file and do it myself.
PM on the way.

[egsols]

Awesome process from concept to implimentation! I am yet another of the many brokenposters.

Are you planning on producing anymore, would be in the market for one?

Forgive my niavety but does jbweld actually work holding the posts on?

[prometheus578]

Never had any problems with the JBWeld. Just did a repair last week. Extra precaution, I coat the mend with finger nail polish as it's pretty resistant to gasoline, needing acetone to remove it.
As for long duration resistance of JBWeld and fuel, I can't say, (I've never reopened a repaired carb to look) but I haven't encountered any problems.
To further my opinion concerning it's gasoline insolvency...
The carbs I finished last week, for some odd reason, one of the brass drain bolts on the bowl had been drilled through and plugged with JBWeld. There was no indication of deterioration on the inside of the bolt, not signs of leakage on the outside.
I'd say that's pretty reliable.

[egsols]

Thanks Prom

I'll have to try that on my spare set. Have two carbs with broken posts. I hope I didn't pitch them, don't think I did on account of SWMBO always going on about how come I keep this and keep that.

[Ken Talbot]

Re: Oddly, or maybe not considering me..."

Originally posted by prometheus578
I don't recall if I addressed this with the first batch.
Those rounded holes for the posts.
The earlier carbs.. their posts are more squarish.. the tool doesn't fit. Is it possable to either square off the corners, or would making the holes "longer' be easier?
Or.. I can just take a jeweller's file and do it myself.

That's what makes this project a bit tricky, the way they changed the shape of the posts from the early model carbs to the late model carbs. I start with 11/64 holes, then elongate them with a 5/32 round chainsaw file. I found last night that the aluminum was much easier to file than the steel was, but I had a harder time keeping the proper shape on the holes.

I sent a prototype off in the mail this morning. Have a look at it and see what you think.

I'm starting to wonder if it might make sense to make these available in aluminum with just round holes, then each end-user could pick up a 5/32 file to elongate as needed for their own carbs. Guys with early carbs could file the less elongated shape, and guys with later model carbs could file the more elongated shape. Sending them out this way would also save quite a bit of time in the manual production process I'm using so far.

[Guy_b_g]

Would this work?



Or would slots make the tool too weak? It'd be easier to make (I think).

[skids]

Re: The first batch is ready!

I obtained and used one of these (or was it a different prototype) and let me tell you it is slick! I have broken a few xs11 goal posts in my days... This thing braces each post simultaneously, which is the only safe way to extract the pins.

Originally posted by Ken Talbot
I'd like to see a few people try these out and provide some feedback. Because these are hand made, there are slight variations in that some fit snugger or looser then others, some of the driving pins are machined a bit on the thin side, etc.

[Ken Talbot]

Originally posted by Guy_b_g
Would this work?



Or would slots make the tool too weak? It'd be easier to make (I think).

Now there'a an idea! It woyld be easy to cut slots to the drilled holes, and the whole thing could be offset to one side to ensure enough strength next to the slots.

That will be the next prototype!

Ya gotta love this kind of collaboration on coming up with stuff like this.

[prometheus578]

Interesting idea from Guy_b_g...
What would be the "cons"?
I note that the new design, Ken, is wider than the old one. With the slots, it would be weaker, but an offset would handle that.
Actually, it really doesn't take as much force to move the pins as we might think. Yeah, they're in there tight, it's just that the posts are made so cheaply that they can't take the stress.
Slippage of the tool I really wouldn't think would be an issue.
If I recall correctly though, the squarish corners on some post wouldn't be an issue if the tool's elongated hole was just a little more elongated.(then the square pegs would fit in the round holes, as the saying goes)
I didn't know that you had filed these by hand... obviously, a straight cut in from the side would be easier. Are you equipped for that kind of precision cutting?
Another question as for using aluminium...
How many threads are cut into the screw hole, and will the aluminium threads take the force applied against it? It probably would... one could always "tap' the tool to give a jarring effect to help release the pin.
I hope I still have some carbs around... that I hadn't already experimented on with the prototype.

[Uncle Heri]

Repair that thing Float Pin Bearingbuck

Hallo Friends,

found you in our'e German XS 650 Forum:

but this Problem seem's international - also this solve, if the "Pin"- tool came to late :


http://www.flickr.com/photos/2232857...69397686/show/