!!!UPDATE TIME!!!
Well I got my stuff from The Edge this week.
Im still waiting on all the parts from my waterjet guy, looks like it may
be a couple of weeks on that.
So I knocked out the front spindles. I used preheat treated 4140,
It comes in around 30 rockwell. It is not too hard but stiffened up a bit.
And machines very well, IMO better that annealed.
Here are some pics of the turning, I didnt take any pics of coping the end
to fit the spindle tube but it was straight foward. I just made a 5deg angled cut with an endmill.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0426.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0433.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0435.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0425.jpg)
Today I went and picked up some aluminum for the gas tank.
Then I decided to work on a tank lid. I really wanted to use the
cap off the GS500 tank. It is a cool flush mount cap.So I had to make a recessed
piece to weld to the tank top, so that I could use the flush mount cap.
Heres a pic of the tank. I had no intention of using it originally
so sitting out side it got mud and paint on it.
![:)](https://madmodder.net/Smileys/default/side2side.gif)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0442.jpg)
Under the cap.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0443.jpg)
First thing I did was make the center plug out of some stainless steel.
This is where the locking section goes.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0444.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0445.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0446.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0447.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0448.jpg)
Next was making the recessed piece that would weld to the tank.
Sawing took almost 45min with my dull blade.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0449.jpg)
Chucked it up, faced and turned back as much as I could.
Then flipped it and faced to length and turned back the other half.
During the last facing operation I used the turning tool to scribe a center line for locating.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0450.jpg)
Then, I bored the center section, to the correct depth for the cap.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0451.jpg)
One thing I noticed , was that the center of the filler tube (SS piece)
Needed to be off center of the recess in the alum. On the GS tank I measued the offset at 3/16".
This has to do with the way the cap hinges and for the locking mechanisim to clear.
I mounted the 4 jaw chuck and got my part mounted so it was offcenter .188".
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0454.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0455.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0456.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0457.jpg)
I then pressed my SS piece in, I wanted to keep my orientation in the 4 jaw chuck so I could bore the
SS piece so I used the tailstock as to help persuade the two to mate.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0458.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0459.jpg)
Well I just realized I didnt take a pic of the finished part. LOL
After that last pic I bored the SS to diameter, then put a 60degree taper like is on the
original. Then polished it us.
Here is a pic with the cap mounted.
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0460.jpg)
![](http://i261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/IMG_0461.jpg)