The New And Improved Unofficial R65 Forum V2

Technical Discussion => BMW Technical Q&A, Primarily R65 => Topic started by: Justin B. on July 20, 2010, 01:34:12 PM

Title: Final Drive Sight Plug Repair
Post by: Justin B. on July 20, 2010, 01:34:12 PM

Oh, the joys of riding an old motorcycle that had lived under a tree for 15 years and was partly disassembled.  When I started riding the Dawg I knew that the sight plug hole had been stripped and what looked to be a 1/8" NPT brass plug had been installed.  It looked/felt secure so I didn't screw around with it.  Yesterday I happened to look down at the final when I had the R/H saddlebag off and noticed "no plug"!!   I guess I can blame it on Bob.  ;)

The hole was already huge and I didn't have a plug big enough so I drilled the hole a bit larger, tapped it M12x1.5, and decided to make some sort of insert.  

I coated the drill bit and tap with sticky grease to catch the chips and then prepared the hole:

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2Fstripped_hole_1.JPG&hash=c0437598bb7f36a48ea2a3d481cfe65a67936268)

I then turned down and tapped a short piece of aluminum to M12x1.5:

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2Finsert_1.JPG&hash=4799ec6d3f5579722b54b781a1f1e5a8c3cf0a60)

Then drilled it through with a 5mm hole and tapped it to M6x1.0:

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2Finsert_2.JPG&hash=8724fd1d9ed4229a7b8284a005384c18ed5b8806)

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2Finsert_3.JPG&hash=4c4b332d10692a4b017a89b29df299088767342c)

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2Finsert_4.JPG&hash=1c44347c009d091e19cdfb601fe8642907cd71e8)


I then parted off the threaded piece I was going to use for the repair.  I inserted a 6mm bolt with lock-nut, coated the insert threads with JB-Weld, and then screwed it into the freshly tapped and cleaned hole.  I flushed both the insert and tapped hole with lacquer thinner before gluing it in.

The insert was first screwed in with low torque:

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2Finsert_installed_1.JPG&hash=fded238d8e128d079f51968fcb77031e901ece43)

Then the bolt and jamb nut were removed after the JB-Weld had set up:

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.squirtworx.com%2Fpics%2F82+R65LS%2FIn+progress%2FFinal+Sight+Plug%2Finsert+installed+2.jpg&hash=5c4c467ba1d8f08bd3ae82ec248233ec8d145881)

I then made a new plug from a 6mm stainless steel bolt and fitted a copper washer:

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2FPlug_1.JPG&hash=f14fd72201d4f4f0a49205057ca81628618a0664)

The new plug was then installed into the repaired hole:

(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fwww.bmwr65.org%2Fhtdocs%2Fyabbfiles%2FAttachments%2FFinished.JPG&hash=f6d6d9134aff2a65643a8cded0e4b0cb170b2e76)

Title: Re: Final Drive Sight Plug Repair
Post by: nhmaf on July 21, 2010, 10:33:05 AM

Hi Justin,

That sounds like a different 'twist' on the the ol' Time-sert/Helicoil approach - unfortunately it seems like there are supposed to be pics with the descriptions, but the pics aren't there?

Title: Re: Final Drive Sight Plug Repair
Post by: Justin B. on July 21, 2010, 11:55:10 AM

Crap...  I don't understand why they are not showing!

Title: Re: Final Drive Sight Plug Repair
Post by: Rob Valdez 79 R65 on July 21, 2010, 04:31:28 PM

Oh!  There are supposed to be pictures?
No wonder I couldn't understand anything.

Title: Re: Final Drive Sight Plug Repair
Post by: mimmo66 on July 21, 2010, 09:15:53 PM

I love it!
It reminds me of friend of mine who could make anything with metal !

Great Job! :)

Title: Re: Final Drive Sight Plug Repair
Post by: Justin B. on July 21, 2010, 09:25:41 PM

CRAP!!!!!!!!

Title: Re: Final Drive Sight Plug Repair
Post by: nhmaf on July 21, 2010, 11:14:28 PM

I am very envious of those folks - like Justin- who have the experience and the tools (lathe, drill press, MIG/stick welders, etc.) to do such fabrications, and then paint them all up so purty afterwards!

Title: Re: Final Drive Sight Plug Repair
Post by: Motu on July 22, 2010, 02:03:55 AM

I wish I could do that with my stripped driveshaft drain plug.There is not enough depth to helicoil it,I'd have to remove the threaded ring to do that,which may mean a new oil seal...seems a lot of work.I've been gluing it in the the last couple of changed - now I'll do a JB job,and pull back the final drive to drain.Until I get sick of that and do the job properly.

Title: Re: Final Drive Sight Plug Repair
Post by: MrRiden on July 23, 2010, 08:57:04 PM

Genius! I love it! Looks the proper repair!

Title: Re: Final Drive Sight Plug Repair
Post by: Justin B. on July 24, 2010, 07:18:27 PM

So far, so good...  After gluing it in I remember thinking, "Dumbass, why didn't you make it out of stainless?"...  

Title: Re: Final Drive Sight Plug Repair
Post by: Ed Miller on July 24, 2010, 10:39:00 PM

Justin, do you have a lathe and a mill?  I have tool envy.  

Title: Re: Final Drive Sight Plug Repair
Post by: Justin B. on July 25, 2010, 04:47:26 AM

Ed, yes, small ones...