Case matching.

The previous owner matched the cases I'm using to some kit pretty deep back so I tried to slope the hero kits transfers to match without going too crazy. I cut the gasket from .8mm rubbery/fibery gasket material. MLM base spacers make making base gaskets so easy peasy. Just trace the skirt hole and stud holes and cut the transfers with an exacto blade when the gasket is on the cylinder. It's worth buying one just to cut your own gaskets since the pre made ones are usualy shit tons off or paper thin junk. Also, I bought crocheting needles at Walmart for a few bucks that were labeled in millimeters. So sick for making cylinders line up perfecto on the studs. Just needed to drill down a little in the cylinders stud holes and press them in. Now it's nice and snug. I also matched the exhaust port to a 26mm gasket since the casting was wayyyyyyy off from the factory. The intake plate was covered with jb weld all around too so there's no chance of leaks. 

Case welding.

Welding aluminium sucks. Puch cases are the thinnest around the crank on top. Thinner than everywhere else at least. I had to do hot tacks around the hole I cut and die grind them flat just to get it built up. Air leaks are my enemy here but that was the best I could do. Straight beads would have just caved in and running my machine at a heat setting low enough not to cave in wouldn't penetrate the metal. After getting it built up I was able to do a few beads with the hot setting. Then die grind it flat and later hit it with a small sanding disk on my drill press. I don't have access to fancy tools... Now I'm ready to weld my plate on from the inside. Not really worried about making the port smaller as it will still flow a huge carb. A vm24 is what I have now from an old Yamaha dt175. I'm pretty nervous, but it's 1/2" thick so at least I won't burn through. I'll seal the deal with epoxy when it's all said and done. I got the transfers welded up too so I can cut massive ports later. 

Cases.

I got a set of cheep e50 cases for the maxi. The lip around the flywheel cover was ground off and they were all crusty and white with some weird crap corroded on them. I gave them a quick sandblasting to take it off and cleaned up  around where the lip used to be since it was uneven. Then drilled and tapped a new hole for the hpi. Not sure if I even needed to, but ohh well. Better to have it and not need it then to need it and not have it I guess. I will weld them up for larger transfers probably this weekend. 

Also started cutting the hole out of the plate for the case induction action. It's not all the way done of course.