KX500 2 piece clutch cover adapter

[Sandblaster]

I like this one the best out of all the others I have tried.
I have tried a few more then I listed.
So, it's time for a little CAD.

CAD 1 KX450F CLUTCH COVER PROFILE.JPG (21.04 KiB) Viewed 15102 times

[Sandblaster]

In fact, the adapter I'm thinking about would look a lot like this one.

RING ONE.JPG (12.16 KiB) Viewed 15100 times

RING TWO.JPG (15.2 KiB) Viewed 15100 times

[Sandblaster]

In the above pics the adapter is about 3/8" too thick.
Here is a better idea of how it will look.

RING three.JPG (12.45 KiB) Viewed 15099 times

RING four.JPG (13.24 KiB) Viewed 15099 times

I might be able to shave another 1/8" off the outer section but I need to do some checking first.

[Sandblaster]

Brain storming last light and figured out a way to make it even thinner
More updates on the way later today

[Sandblaster]

Ok, right now I have a total thickness of 1/2" for the adapter.
Unfortunately that would make the outside of the KX450F clutch cover stick out approximately 1/2" past where the stock clutch cover ends...
I can easily make the adapter thinner.
However, I am concerned about thread engagement with the aluminum.
Take a look at the pics below.
Right now I am set up for a full 1/2" of thread engagement.

BOLT LENGTH.JPG (21.62 KiB) Viewed 15092 times

In reality I know this is overkill as there won't be any real stress on it.
However, there is always the guy who over-tightens everything....
So in your opinions, what would be the safe amount of thread engagement?
After all, the thinner the adapter, the closer to the original cover position we can get which means less tweaking of the rear brake lever...

[Tardboy]

Who does your CAD work?

[Sandblaster]

I do.

[Sandblaster]

Here is a pic with the cutaway clutch cover that is being adapted.

MEASURING 1.JPG (64.85 KiB) Viewed 15087 times

Measuring to be sure we have the correct clearance.

MEASURING 2.JPG (29.42 KiB) Viewed 15087 times

Looks like I am right there

GETTIN THERE PRINT.PNG (26.31 KiB) Viewed 15087 times

[Sandblaster]

Sitting in the CNC:

Sitting in the CNC.JPG (32.48 KiB) Viewed 15082 times

I had the clutch cover machined today to the correct depth.

FINAL DEPTH.JPG (60.3 KiB) Viewed 15083 times

[Sandblaster]

Fitment on the bike

FINAL DEPTH INSTALLED ON THE BIKE.JPG (104.42 KiB) Viewed 15083 times

FINAL DEPTH INSTALLED ON THE BIKE 2.JPG (90.78 KiB) Viewed 15083 times

FINAL DEPTH INSTALLED ON THE BIKE 3.JPG (58.85 KiB) Viewed 15083 times

FINAL DEPTH INSTALLED ON THE BIKE 4.JPG (85.96 KiB) Viewed 15083 times

FINAL DEPTH INSTALLED ON THE BIKE 5.JPG (79.72 KiB) Viewed 15083 times

Plenty of room for the rear brake lever.
The adapter will make the cover stick out about 1/8" further then shown but still there is plenty of room...
Now I just need to take a few more measurements and finalize the print for production...