Making your own copper head gaskets

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sportston
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Making your own copper head gaskets

Post by sportston »

Dollydog suggested making a new topic.
Since DD has made a few gaskets from copper sheet we thought it a good idea to add the info to a dedicated topic.
"what do i use to cut the edges? i presume you mean round the stud holes etc? SCISSORS :D decent scissors will easily cut
thin copper, where tin snips tend to curl it up. i ALWAYS cut the centre hole first, followed be the stud holes, followed by the final shaping :D
cheers, dd."
DD uses 0.3mm or 0.5mm copper sheet and cuts the centre holes for head gaskets using an adjustable tank cutter like this.
http://www.ebay.co.uk/itm/Priory-201-C- ... 2682744220
and says that "before you start you must screw the corners of the plate securely to a block of wood and make sure it's dead flat"
I am guessing a pillar drill very gently applied to the job would be best at cutting accurately.

Feel free to chime in DD if you have any revisions or further advice.
rngdng
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Re: Making your own copper head gaskets

Post by rngdng »

I tried a copper head gasket on my Buffalo, and it quickly developed a water leak. I went back to the stock one. For anything else, I'm sure copper is the way to go.



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dollydog
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Re: Making your own copper head gaskets

Post by dollydog »

hi lane, aren't kettle head gaskets composite? i've used mostly 0.3mm copper on alsorts of gt's with no problems. they are head and shoulders better than those pattern aluminium ones i used to buy,[vesrah are the worst of the lot] and they last virtually forever. put them on the gas ring til cherry red and drop them in some cold water. they come out like putty :D i'll try and put some photo's up when i get chance. i needed to lower the compression on my gt285 and my big bang, so i used 0.5mm and after that they were no trouble. :D
cheers, dd.
GTS250 road registered. TS250 engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.
dollydog
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Re: Making your own copper head gaskets

Post by dollydog »

are you sitting comfortably? then i'll begin :D
the start: note, the right edge was cut with tinsnips, the others with scissors - much neater.
Image
viewtopic.php?f=9&t=13132" onclick="window.open(this.href);return false;
trepanner at the ready:
Image

middle cut out:
Image

done - and cut with scissors :D plus an old one and a pattern. 20 minutes work!
Image

cheers, dd.
GTS250 road registered. TS250 engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.
sportston
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Suzuki 2-Strokes: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S

Re: Making your own copper head gaskets

Post by sportston »

Lovely. thanks DD
dollydog
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Re: Making your own copper head gaskets

Post by dollydog »

there was another piccy between 3 and 4, but my mrs disturbed me and i couldn't remember if i'd photo'ed it. obviously not :D but it was only some 12mm holes being bored :D
the insulators between the carbs and barrels are the best. 10mm thick tufnol and a lot of elbow grease :D
cheers, dd.
GTS250 road registered. TS250 engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.
sportston
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Posts: 1119
Joined: Wed Jul 10, 2013 12:04 pm
Country: England, UK
Suzuki 2-Strokes: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S

Re: Making your own copper head gaskets

Post by sportston »

dollydog wrote:there was another piccy.... it was only some 12mm holes being bored :D
Your drill the holes? I thought you would punch them.
dollydog
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Suzuki 2-Strokes: several gt250 ramairs

Re: Making your own copper head gaskets

Post by dollydog »

if i had a punch i probably would do. the holes need to be done very carefully or they rip and make a right mess.
best way to do them is with a piece of plate steel with a 12mm hole in it, clamped over the hole you're going to drill,
[2 pairs of mole grips are fine] that way they can't rip and are much neater :D
0.5mm copper is far less prone to ripping than the 0.3mm and i just centre drill them, then 12mm drill, then counter sink bit
[which is about 12.2mm :D ]. edges are fine. go over it with a sanding block and take all the sharp edges off
and you're done. looks very professional, and best of all, doesn't leak :D
cheers, dd.
GTS250 road registered. TS250 engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.
sportston
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Posts: 1119
Joined: Wed Jul 10, 2013 12:04 pm
Country: England, UK
Suzuki 2-Strokes: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S

Re: Making your own copper head gaskets

Post by sportston »

Interesting. I have some punches I usually use for making gaskets so usually use them. Quite cheap and reliable but not sure if they will work well with copper or not. I may try both methods and see which is easier.
dollydog
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Re: Making your own copper head gaskets

Post by dollydog »

yes, i've got a full set of hollow gasket punches, i never thought of using them :D
dead handy when making clutch side gaskets, as long as you punch the holes out BEFORE you
cut the outline out, otherwise they tear across from the hole to the edge, which is annoying :D
i always start with a square, punch the small holes, then cut the middle out, then the outline :D
i thought you meant the machine punches for steel etc :D
cheers, dd.
ps, yes, i do like smilies :D
GTS250 road registered. TS250 engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.
sportston
Expert racer
Posts: 1119
Joined: Wed Jul 10, 2013 12:04 pm
Country: England, UK
Suzuki 2-Strokes: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S

Re: Making your own copper head gaskets

Post by sportston »

No I don't have any punches for steel. I'm not very good at metalwork and I don't seem to have much of a knack for welding. Maybe if i did a lot of it I would get better, but I think it is because I have no artistic flair.
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