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Old 08-19-2010, 08:40 PM   #1
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Who knows how to drill and tap aluminum?

Wanting to start riding again, so i want a steering damper for the duc. Last time I took out several months back the front seemed a little sketchy when I was shittn and gittn. Dan Kyle makes an Ohlins linear damper kit but since the 848 didn't come with one you have to drill and tap the top triple to install the kit. Anyone know how to do this?
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Old 08-19-2010, 09:02 PM   #2
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yup, its easy, depending on location. drill hole to size recommended by tap of choice, then slowly tap using wd on the tap and wallah, threaded hole before you know it.
Aluminum is very easy metal to work with, you can do it!!
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Old 08-19-2010, 09:09 PM   #3
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Is it really that much different from steel? I tried to drill and tap a hole on a steel control arm and it was a major fail. Kept the tap lubed but it just wallered out the hole
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Old 08-19-2010, 09:10 PM   #4
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Verify the tap size, whether it's metric or not. For a high load mount like a dampener, I would look into Helicoil inserts.. they add steel threads to the aluminum holes.

Main thing is take your time, verify everything is square and you have the correct drill size. I also prefer Tap Magic to WD 40.
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Old 08-19-2010, 09:20 PM   #5
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Quote:
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Verify the tap size, whether it's metric or not. For a high load mount like a dampener, I would look into Helicoil inserts.. they add steel threads to the aluminum holes.

Main thing is take your time, verify everything is square and you have the correct drill size. I also prefer Tap Magic to WD 40.
Yeah one of my many concerns of me doing it, is I don't have a drill press and if the hole isn't straight it will drive me insane
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Old 08-19-2010, 09:25 PM   #6
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Tempted to get a rotary style dampener and call it a day, but they look out of place on a Duc
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Old 08-19-2010, 09:32 PM   #7
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Quote:
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Yeah one of my many concerns of me doing it, is I don't have a drill press and if the hole isn't straight it will drive me insane
Don't need a press, my ez-out set came with drill guides, to keep the bit square to the material. Any good tool store should have them, as well as metric taps.
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Old 08-19-2010, 09:42 PM   #8
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half the chore is having the right equipment, buy the right tools, i prefer snap on ive had mac matco and others but i prefer snap on tools. as my father used to say grab ur nutz and just do it.
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Old 08-19-2010, 09:46 PM   #9
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i was looking at the kit and would it be possible to just drill all the way through, then use a longer grade 8 allen bolt with a nut and locktite?

if drilling and tapping doesnt work then you could possible drill all the way through.

but yes like jgixer's dad said. grab your nuts and just dooooooo it.
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Old 08-19-2010, 09:50 PM   #10
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Quote:
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half the chore is having the right equipment, buy the right tools, i prefer snap on ive had mac matco and others but i prefer snap on tools. as my father used to say grab ur nutz and just do it.
Have full access to just about everything snap on makes. Just still uneasy of drilling a hole on the bike
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Old 08-19-2010, 09:54 PM   #11
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Quote:
Originally Posted by philly fresh View Post
i was looking at the kit and would it be possible to just drill all the way through, then use a longer grade 8 allen bolt with a nut and locktite?

if drilling and tapping doesnt work then you could possible drill all the way through.

but yes like jgixer's dad said. grab your nuts and just dooooooo it.
Not sure I would have to look, cause if there's a nut on bottom it might rub the fuel tank
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Old 08-19-2010, 10:02 PM   #12
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attachmentphp?attachmentid40188&ampd1228078525

whats below this. as this is what you are attempting to drill through. i dont think the tank is below it.
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Old 08-19-2010, 10:04 PM   #13
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only thing that would scare me about putting in helicoils is the dissimilar metals would cause galvanic corrosion.
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Old 08-19-2010, 10:08 PM   #14
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Take it to a automotive machine shop. They will drill it straight and install a steel insert. No corrosion worries. Find a shop that uses TimeSerts if possible. They are the bomb.
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Old 08-19-2010, 10:09 PM   #15
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That's what I need to drill, not sure what's on the other side, might be open I never really looked that hard
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Old 08-19-2010, 10:10 PM   #16
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Call Owens in Pearland. They can hook you up.
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Old 08-19-2010, 10:11 PM   #17
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Take it to a automotive machine shop. They will drill it straight and install a steel insert. No corrosion worries. Find a shop that uses TimeSerts if possible. They are the bomb.
What's a TimeSert?
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Old 08-19-2010, 10:11 PM   #18
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should be open. its where the top tubes meet the head tube. top tree just would swivel in between the frame and those wings on the edges of what you are drilling seem to be turn limiters. good luck with the install. im sure it seems daunting.


they are these little bad motherfockers.

http://www.timesert.com/
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Old 08-19-2010, 10:37 PM   #19
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Quote:
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Call Owens in Pearland. They can hook you up.
Thanks ill give them a call

Quote:
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should be open. its where the top tubes meet the head tube. top tree just would swivel in between the frame and those wings on the edges of what you are drilling seem to be turn limiters. good luck with the install. im sure it seems daunting.


they are these little bad motherfockers.

http://www.timesert.com/
Ok I think the aircraft mechanic at work was just telling me about these, its sounds like the description he gave me but he didn't know the name.
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Old 08-19-2010, 11:34 PM   #20
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Quote:
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only thing that would scare me about putting in helicoils is the dissimilar metals would cause galvanic corrosion.
That shouldn't really be a issue. There would need to be an electrolyte present.
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