Felt washers, swinging arm (500) and carbs.

[SPR]

Arrived safe and sound

[Oddjob]

Yes Dave, the lifter arms are the same as the 500/550 ones, it's the choke mechanism ones I can't make at present, I need to order some odd size cutters to be able to do those. Tried 10mm and 6mm and the bar just cuts them to bits when inserted, tried 8mm and 6mm and the wall is too thin for any strength and again the bar wrecks them. 6mm is too small for the inside, the bar is 6.8mm so the threads on the end of the choke bars just pull it to pieces going through. I have a 6.5mm cutter on order which may work.

Send me a PM Dave with your address and I'll advise on PayPal address, unless of course you've bought from me before, in which case you'll know it.

[Oddjob]

Finally managed today to order some new cutters so I can attempt to make the choke mechanism washers. Not sure how long they'll take to arrive, I'll let you know when they do and how the attempt to recreate these washers go.

I have today done a couple of the brake arm washers that go between the brake arm and the brake plate on the 500. I have to hand make these as the sizes required mean they don't mount on the same tool at the same time, unlike the lifter arm ones. I had to order a special cutter to enable me to use both cutters on the same tool for the choke arm ones, whether this will work is up for debate.

[Bryanj]

Well done Ken, your dilligence is appreciated.

[Oddjob]

Manufacturer has posted them, we'll need to see when they are delivered in France, then reposted onto me. Could be a week or so before I can trial run these washers.

Another £100 for new cutters. Gonna take a while to get that money back, saying that if I do what Mike Nixon did and charge $5 each I'd make it back in no time. No idea how he could justify that price, they are easy to make with the right tools and felt isn't exactly dear. Most of my charges are postage.

Might throw a few sets on Ebay, widen the market so to speak.

Saying that, how do you justify this.
https://www.ebay.co.uk/itm/254973783563?_trkparms=amclksrc%3DITM%26aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D242152%26meid%3D4482dd5c73ef4c7e976b8ce380709989%26pid%3D100675%26rk%3D2%26rkt%3D15%26sd%3D314106278968%26itm%3D254973783563%26pmt%3D1%26noa%3D1%26pg%3D2380057%26brand%3DHonda&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3A653673cd-38ef-11ed-b9f0-261dedc53b0f%7Cparentrq%3A5b45aca51830aa7105eaae8cfff79ba6%7Ciid%3A1

Initial cost is pretty reasonable, but look at the postal charges, there is NO weight in these items at all.

[Bryanj]

Said free postage when i looked

[Oddjob]

Says £19.40 on my screen.

Just looked at it was to the USA for some reason it thought I was there.

[Nurse Julie]

Yes, free post, it's Fowlers of Bristol.

[Oddjob]

I wonder how Fowlers can do that price, I mean £2.40 is a decent price for the washer alone but free postage, the cost these days would mean they are virtually giving those away.

News.

Cutters have arrived in France, they are now being sent onwards to me possibly tomorrow. Should have them with a week I reckon. I'll then do a test run and see how the choke washers come out. We can only hope.

[Bryanj]

Its the discount they get from Honda and franked mail is cheaper than stamps mate.
Hope the new felts work or i am going to have to get creative for comfys carbs!

[Trigger]

Part number 45134-250-000 is only 47p trade price 

[Oddjob]

That's a good price TBH.

[Oddjob]

Cutters arrived today.

Results were not good. I got 6 different sizes, all around the size of the choke shaft and the opening the felt washers sits in.

A little explanation first. Most people make these washers by first of all cutting out either the large or the smaller openings, both have there plus and minus points. My tool has 3 positions for the cutters, the smaller ones thread onto the central boss, which is shaped like a hammer. These go up to 10mm, after 12mm you use the middle boss, these go up to 20mm, after that they can get pretty big and those use the outer and biggest boss. So in theory you can pair 2 or even 3 cutters together, which makes them ideal to make washers. The problem is the choke mechanism washers are small, the central shaft is 6.8mm wide and the opening is just under 9mm. Cutters in sets don't come in half sizes, fill mmm only. So the closest you can get is 6mm and 10mm but as explained these use the same threaded boss so you can't do that, so, you're back to the first method. Tried 6mm and 10mm before deciding they don't work, 10mm is slightly too big to go in the opening and 6mm is too small for the shaft, yoiu can force them in there but the shaft is threaded and when you go to push it through the threads catch the felt and just rip it too bits.

So new cutters are required. I bought 6.5mm, 7.5mm(just in case), a special 6.9mm one(you never know), a 9mm, a 9.5mm and a very special 10mm one that been made to use the middle boss instead of the central threaded boss.

So I tried 6.9 x 9.5 first, had to cut them by hand and frankly it's as good as impossible, most tear as the wall is only 1.35mm wide and that's if you get the cutters 100% central, most go off centre and that's that ruined. So you need to increase the wall size, so 6.5 x 9.5, nope, still virtually impossible. You need 7 of these for each bank of carbs, making one involves numerous failures. I could make a set if you're willing to pay £20 for 7 as I'd ruin 90% of them making them. I tried 6.9 x 9 and 6.5 x 9 and still not much better.

I'd already tried the special 10mm cutter which allows double cuts so makes perfect washers virtually everytime, however I didn't like how they fitted, so went back to the first method again.

So can I make them?

Yes and No.

Yes, I can so long as I use 10mm x 6.9mm, the inner hole is big enough not to foul the threads as they pass through, so you can actually thread the felt washer onto the shaft on one side, pass it through the carb body and then fit the other side, I tried that and it's possible, a thin screwdriver and you can actually get the washer to sit inside the opening, a little thin oil on it and it would also lubricate the shaft as it moves as well as sealing it from outside dust and air ingress.

As per pic.



Bryan you want to be the test dummy? if you say they are ok I'll do some more, if you say no then I'll not do them.

[Bryanj]

I will happily do that Ken, send some down and i will try and build asap mate

[Erny]

Hi Ken,

anything new on this topic with felt washers?

I can check with local company who did D-rings last time, maybe they can do also these felt washers too?