DIY clear belt covers

[the_adam]

Hi all,

Had my eye on some of those shiny belt covers with windows in for a while. But why spend nearly £300 on something when you can make it yourself? :) So here's the sum of my evening's work. Quite pleased with it really, I don't have a dremel or anything so it was a hacksaw and file job. Shame I didn't have time to finish the other one, I'll just have to find another spare evening...

http://i1014.photobucket.com/albums/af266/the_adam_m695/DSCF0615.jpg

Will get another photo of them fitted when they're both done :)

[He11cat]

Nice work !...

[the_adam]

Thanks :)

If only housemates didn't need to sleep I'd probably have both of them done by now...It does look a bit more homemade from the back. But noone needs to see that side!

Although having it sat on the floor has just reminded me that I have to be up in 5 hours to put them back on before work... :worried:

[utopia]

Ooh, nice work. I really like those.
My covers are the five piece ones, with little inspection covers half way along, so there isn't much room for clear sections, but now that I've seen those I'm seriously thinking of swapping mine and doing the same.
I like the look of visual mechanicals, and the reassurance of being able to see that all's well with the belts from time to time, but my nerves wouldn't stand having open covers, and it would offend my engineering sensibilities anyway.
Have you lost much, or any, clearance to the edges of the belts ? I only ask because my 750 had a manufacturing defect on the double pulley which chafed the teeth off the outer edge of the belt, which then moved outwards until it began to cut into the belt covers like a bandsaw. The point being that I now know that there isn't a lot of clearance available, at least not on my 750 engine.
That experience, and a former ford escort that snapped a cambelt, is the reason that I like to be able to see the belts.

So, having written the above, I've just had a look at my old belts, and measured the damaged one with a micrometer. I was surprised to find that the belt had only moved outwards by a maximum of about 1mm, possibly less. That was enough to foul the covers. I hate to sow any seeds of worry, particularly at this late hour, and anyway your engine may not be exactly the same as mine. It certainly has different covers in the first place. But it might be a point to be aware of, and take into account when you refit and try them.
I wonder if its possible to space them a little bit further out with suitable washers, at least on the first run (or if you're now worried by what I've said...sorry 'bout that).

[the_adam]

It is something I'd worried about. Before doing anything I put some thick carpet tape over the inside of the covers and refitted them to see if anything would mark it, and all looked ok. It seems that the little raised sections in them aren't actually needed on my bike (unless they're there to add a bit of extra clearance), I'm assuming more than one model shares the same cover.

Had plenty of washers available when I finally fitted it too but it doesn't appear to need them. The material's 2mm lexan so hasn't added a huge amount of thickness, although admittedly it's more than your 1mm :eyepopping: I got to work ok, going to keep an eye on it though :)

My main concern at the moment is the window staying in, the epoxy I put it in with is rated to over 120 degrees and the outside was only a little warm when I got to work though. Should hopefully be safe enough...Adams just worry a lot!

[Dookbob]

I,m with Utopia on this one , I had the same problem on one of my M600 where the belt shifted ever so slightly and cut a groove in the cover. After saying that, I do like the idea of windows though, because like Utopia I have an engineering background that tells me without a shadow of a doubt that running with the belt covers off is an absolute NO NO.
Nice job though Adam, by the way what kind of a supplier do you get "Lexan" from, I have never heard of the stuff, unless its just another name for perspex, or polycarbonate. I,m going to give this one some thinking about to see if I can come up with a mark 2 version that gets round the clearance thingy. Could even arrange an LED to illuminate the belt space, these are the things you dream up when you have time on your hands.

[the_adam]

Yep, I've got the engineering background too :) Open belts might be ok on a show bike but it's definitely not for commuting. Think it looks better like this anyway to be honest, the side of the engine isn't that nice to look at really! I'm wondering if a bit of paint on the edge of the belts might look good, it probably wouldn't last very long though...

Lexan is just a trade name, it's a polycarbinate. I got it online (DIY shops only seem to have greenhouse-sized sheets!) but forget where from now, I'll have to look it up when I'm home. Still had to buy a bigger sheet than I needed so think there may be enough for someone else to use my leftovers assuming I don't make any mistakes with the second one :thumbsup:

Also, I think I'll put a couple of washers on them just to be safe!

[Rally]

Lexan is a better quality type of 'perspex' with more resilience to breakage. It is what Harley and Triumph us on their screens these days. I think it is also meant to resist UV rays better from yellowing.

[gary tompkins]

If you could mill a recess in the edge using router cutter, the lexan could sit flush with the outer cover face and give more inner clearance for belts. Lexan is a trade name for polycarbonate which has been around since 1953. Used by NASA, the military and car manufactures it's very impact resistant and even able to stop bullets.

[the_adam]

Hi Gary, that's how I would have done it ideally, but with only (very poor quality) hand tools I doubt I could have done it accurately enough. It took long enough to get it looking like this already :) If I ever come across one I might get a couple of new windows made up for it though. Until then I'll just stick some spacers in to put my mind at rest!

[rac3r]

I've been thinking about this for a while. You've done a good job! Maybe you should sell them for £200 :chuckle:

[digga]

for large or small amounts of 'Lexan' Polycarb' etc try : Polybron in Shepshed
Unit 4c
Gelders Hall Road
Loughborough
Leics
LE12 9NH
01509 507123


I used them alot when i was signmaking : )
explain to the woman that answers the phone what you need it for ---- she's good ..

[the_adam]

Did the other one last night. Not quite such a neat job on the window unfortunately, overcut it very slightly so you can see the edge, I might redo it one day... You were right though, this one didn't fit back on again (the vertical one had well over 5mm clearance so that was fine as it was). I had to put it out so far I ran out of washers so ended up improvising with a couple of small fuel hose clamps where they couldn't be seen :thumbsup:

Trouble is the stacks of washers make it very awkward to fit, think I'll make up some kind of permanent spacers to attach to the covers next time they're off. I dropped one of the last ones...it wedged itself in behind one of the rollers and I had to start again :( At least the windows let me see where it was though!

Rac3r, I like your thinking...of course I wouldn't want to spend so long making myself another set, so maybe call it £200 and a dremel :chuckle: Doubt anyone would want to buy these to be honest, I'm happy enough with how they went but it's obviously homemade when you look closely. Pictures this evening...

[rac3r]

From the pics they look pretty much like the ones I've seen for sale, imagine how much of a margin they must be making on them :eek:

[utopia]

Ah, yes. It was the belt on the horizontal cylinder that fouled the covers on my bike. Forgot to specify that.
I have a little lathe in the shed. If you need some spacers making to replace the washer stacks, and you're not in too much hurry, I could knock you a set up if you send me the dimensions. It might be a while until I can find, rather than buy, something to make them from, and I'm notoriously slow at getting round to such things, but the offer's there if you don't mind a bit of a wait.

[the_adam]

Thanks for the offer Jeff, I've had another possible idea though... I've got the little rubber spacers that were between the cooling fins before I painted the engine. If I could borrow a drill and make a hole in the middle they may just be the perfect size. Maybe :)

Did you manage to find out how much the panels would cost to post by the way?

[Dukedesmo]

I've got the little rubber spacers that were between the cooling fins before I painted the engine. If I could borrow a drill and make a hole in the middle they may just be the perfect size. Maybe :)



Tap washers?...

[the_adam]

Tap washers...that's exactly what I need :D You, sir, deserve a cookie :)

Here are the promised pictures from this evening. Sorry the bike's not very clean...this was done in the hours between between a week of commuting to work and a trip back to Yorkshire so there wasn't really much point. And I still need to replace that crash bung...

http://i1014.photobucket.com/albums/af266/the_adam_m695/DSCF0619.jpg

http://i1014.photobucket.com/albums/af266/the_adam_m695/DSCF0620.jpg

Strangely fascinating to watch, I had the neighbours come to stare at them for a while too :)

[Dave G]

Put a spot of paint on the edge of the belt somewhere, possibly on the rollers too and watch the almost electric effect of it spinning.:yoparty:

[number24]

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[Dukedesmo]

Looking very good. :thumbsup:

[the_adam]

Thanks!

Make me some! Make me some! Make me some! Make me some! Make me some! Make me some! ...etc :)

If I can find some slightly better tools to borrow (when I get back) I could always give it a go...obviously you'd have to send me your covers and there would be the slight possibility of me making a mess of them though! Also, the bike's only done about 70 miles since I did this so can't say for sure how well that epoxy putty will last yet :)

[number24]

I could be up for that. Need to get some flat ones though, like without the viewing cap.

Thanks

[He11cat]

Well done :) they look good and you brave trying it so what if home made .. Sometimes it's more fun ..

[a7avenger]

Nice job, well done!

[the_adam]

Glad people like them...they've certainly been getting a bit of attention too :) Trouble is I'm getting crazy ideas about trying it with carbon covers now... Maybe one day :D