REF: Engine Mechanicals - Sub-03A

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====== REF: Engine Mechanicals - Sub-03A ======
====== Ignition Cover Mods and Aftermarket Covers ======
**See also**: \\

  * [[techtalk:ref:engmech03e#chopping_the_cam_gearcase_cover|Chopping the Cam / Gearcase Cover]]
  * [[techtalk:ref:engmech03f#pics_of_cam_gearcase_cover_mods|Pics of Cam / Gearcase Cover Mods]]
  * [[techtalk:ref:engmech03j#pics_of_sprocket_cover_mods|Pics of Sprocket Cover Mods]]
  * [[techtalk:ref:svcproc45#refshop_notes_and_tips|Polishing Aluminum]]

====== Custom / Homemade Covers ======
===== Make Your Own Ignition Cover =====
|Trace your existing cover out onto the material of your choice (aluminum used here). ((photos by bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/191167-sportster-primary-material?highlight=jig#post4123797))|||
|{{:techtalk:ref:engmech:homemade_ignition_cover_1_by_bustert.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_ignition_cover_2_by_bustert.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_ignition_cover_3_by_bustert.jpg?direct&300|}}|

|Rough cut the round disc. ((photos by bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/191167-sportster-primary-material?highlight=jig#post4123797))|||
|{{:techtalk:ref:engmech:homemade_ignition_cover_4_by_bustert.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_ignition_cover_5_by_bustert.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_ignition_cover_6_by_bustert.jpg?direct&300|}}|

|Drill the mounting holes. \\ Then make a jig to hold the disc into a lathe or drill press. \\ Turn or file the edges to the target diameter and with the finish of your choice. ((photos by bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/191167-sportster-primary-material?highlight=jig#post4123797))|||
|{{:techtalk:ref:engmech:homemade_ignition_cover_7_by_bustert.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_ignition_cover_8_by_bustert.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_ignition_cover_9_by_bustert.jpg?direct&300|}}|

===== Commercial Iron Cross with Green Backdrop =====
  * Parts:
    * 1 green acrylic plate from any dime or thrift store.
    * Aftermarket ignition cover with the iron cross emblem.
  * Tools:
    * Jig saw with the wider teeth cutting bit. \\ (the fine bit teeth will melt the plastic before cutting it)
    * A file to smooth out the edges.
    * A drill to make the mounting holes.
    * Painter's tape to protect the acrylic.
    * A marker to outline the material.

|Acrylic is hard to work with. If you go too fast it melts back together. \\ If you go too slow it cracks. \\ The steel iron cross overlay will hide imperfections on the edges of the acrylic. ((photos by Johnny Wolf of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-accessories/54611-since-everyone-seems-to-be-going-green-timing-cover-mod?t=263640))||
|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_7_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_8_by_johnny_wolf.jpg?direct&300|}}|

|The backdrop is made from a cheap acrylic plate. \\ Trace the cover onto a taped section of the plate and cut it out with the jigsaw.  ((photos by Johnny Wolf of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-accessories/54611-since-everyone-seems-to-be-going-green-timing-cover-mod?t=263640))|||
|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_1_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_2_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_3_by_johnny_wolf.jpg?direct&300|}}|

|Drill the mounting holes. \\  Then bolt it to the original cover to act as a guide for filing the edges smooth. \\ The blue overhang below is the material that had to be removed. ((photos by Johnny Wolf of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-accessories/54611-since-everyone-seems-to-be-going-green-timing-cover-mod?t=263640))|||
|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_4_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_5_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:ref:engmech:iron_cross_with_green_insert_ignition_cover_6_by_johnny_wolf.jpg?direct&300|}}|

===== Homemade Finned Ignition Cover =====
|Start with some aluminum stock ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173940-homebrew-points-cover?threadid=1865634))|Drill the mounting holes ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173940-homebrew-points-cover?threadid=1865634))|Make a backing plate as above to fit in a lathe. ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173940-homebrew-points-cover?threadid=1865634))|
|{{:techtalk:ref:engmech:timing_cover_1_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_2_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_3_by_freewheeler.jpg?direct&300|}}|

|Bolt the backing plate to the disc, chuck the plate up into a lathe and cut it down to right diameter. ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173940-homebrew-points-cover?threadid=1865634))||The back of this one was chamfered. ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173940-homebrew-points-cover?threadid=1865634))|
|{{:techtalk:ref:engmech:timing_cover_4_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_5_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_6_by_freewheeler.jpg?direct&300|}}|

|Next, put the disc on a milling machine to cut the fins. ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173940-homebrew-points-cover?threadid=1865634))|||
|{{:techtalk:ref:engmech:timing_cover_7_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_8_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_9_by_freewheeler.jpg?direct&300|}}|

|Polish out the machining marks and install. ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173940-homebrew-points-cover?threadid=1865634))||
|{{:techtalk:ref:engmech:timing_cover_10_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_11_by_freewheeler.jpg?direct&300|}}|

====== Pics of Homemade Covers ======
|Ignition cover made from a recycled burnt out \\ .010 over piston ((photo by Inked01 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/140988-new-ignition-cover?t=1528258))|
|{{:techtalk:ref:engmech:piston_head_ignition_cover_by_inked01.jpg?direct&300|}}|

|Timing cover made by drumballer ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/64458-i-made-timing-covers?t=403831))|As sold to flourman ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/64458-i-made-timing-covers/page4?t=403831&page=4))|||
|{{:techtalk:ref:engmech:ignition_cover_made_by_drumballer.jpg?direct&300|}} |{{:techtalk:ref:engmech:timing_cover_1_by_flourman.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_2_by_flourman.jpg?direct&300|}}|

|  Brass ignition cover. ((photo by AussieGazza of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/87710-aussiegazzas-rebuild/page10?t=692835&page=10)) ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/87710-aussiegazzas-rebuild/page16?t=692835&page=16))  ||  
|{{:techtalk:ref:engmech:brass_ignition_cover_1_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:ref:engmech:brass_ignition_cover_2_by_aussiegazza.jpg?direct&300|}}|

====== Pics of Aftermarket Covers ======
|{{:techtalk:ref:engmech:timing_cover_by_jrogers329.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_1_by_biknut.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_by_rollbar.jpg?direct&300|}}|
|Timing cover by jrogers329 ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/47449-i-found-a-custom-timing-cover/page2?t=180329&page=2))| Timing cover by biknut ((http://xlforum.net/forums/showthread.php?t=180329&page=2))|Timing cover by Rollbar ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/173216-timing-cover-attachment-reattachment?t=1859176))|

|{{:techtalk:ref:engmech:timing_cover_2_by_biknut.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_3_by_biknut.jpg?direct&300|}}|
|Timing cover by biknut ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/47449-i-found-a-custom-timing-cover?t=180329))||

|{{:techtalk:ref:engmech:timing_cover_by_rottenralph.jpg?direct&300|}}|{{:techtalk:ref:engmech:timing_cover_by_sportytrace.jpg?direct&300|}}|
|Timing cover by rottenralph ((http://xlforum.net/forums/showthread.php?t=180329&page=2))|Timing cover by sportytrace ((https://www.xlforum.net/forum/vendors/figure-machine/151606-thanks-for-the-custom-timing-cover?t=1636813))|


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