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タンクキャップからのガソリン漏れ対策です。 [KV75]

経年劣化のため、タンクキャップからのガソリン漏れが酷いです。
一応、キャップ裏のパッキンや、ガソリン給油口の錆を落として、油砥石で慣らしたりして、パッキンからのガソリン漏れはなくなりましたが、今度はキャップ上部の空気穴からガソリンが漏れてきました。
さぁどうしましょう。

「良さげなキャップがありますから試してみましょう」
とオーナーさんからの提案で、画像のキャップを試してみましたが、キャップ裏のでっぱりのサイズが大きくて、うまくはまりません。

0001.jpg

キャップ裏のでっぱりがぁ・・・


そこで、キャップ裏のでっぱり部分を、私が自作することにしました。
まずは、バンドソーで鉄丸棒(S45C)を切り出し、ミニ旋盤にて削り出します。

0002.jpg0004.jpg0005.jpg0006.jpg0007.jpg0008.jpg0009.jpg0010.jpg

ミニ旋盤だけに、削るのに時間が掛かりました。


切削手順は

① 端面削り
② 外形削り
   この後の中繰りのために出べそを作ります。
③ 外形削り
   出べそをチャックに挟んで、目標のサイズまで外形を削ります。

バイトは、超鋼ろう付けチップで自作したバイトです。

ミニ旋盤は切り込み量が小さくなるので、時間が掛かります。
150Kgクラスの卓上旋盤も持っているのですが、訳あって今は手元にありません。

外形が出来たら、次に中繰りを行います。

0011.jpg0012.jpg0013.jpg0014.jpg

中繰りは外形削りよりも時間が掛かります。


中繰りバイトも自作バイトを持っていたのですが、チップが割れていて使用できませんので、外形削り用のものを加工して無理して使っています。

中繰りが終わったら、出べそを切り離してしまいましょう。

0015.jpg0016.jpg

小さめになっていますが、分かりにくいですかね。


ここまで出来たら、次にオリジナルに合わせてネジ穴やロック用の溝を切って行きます。
まずは、ネジ穴の位置を合わせるために、マジックでしるしをつけます。
サイズが小さいので、オリジナルを上にかぶせて、穴位置を合わせました。

0017.jpg0018.jpg0019.jpg

しるしに合わせて、ドリルで穴を開けました。 手抜きをしたので、斜めに開ける穴がズレちゃいました・・・。


ロック用の溝は、糸鋸とヤスリを使って切って行きます。
ちなみに、糸鋸は私の肥後象眼の師匠に作っていただいたものです。刃を止める箇所がイモネジで止めるようになっているので、小さなスペースでも切ることができ、とても使いやすいです。

0020.jpg0022.jpg0023.jpg

工作は楽しいですね。時間が経つのを忘れます。


糸鋸で横に切る場合には、刃を90度横に取り付けます。
刃は、バローベの#1を使っています。とても良い切れ味です。糸鋸にしろヤスリにしろ、ヨーロッパ製は良いですね。時計職人用に発達したのでしょうか。
私のヤスリは、魚地球の組みヤスリです。バローベは高くて・・・。

0034.jpg0024.jpg0025.jpg

出来上がりはこんな感じです。


さぁ出来た部品を持って、ショップへ行ってタンクキャップに合わせてみましょう。

0026.jpg

さぁ現物合わせです。


バネが入らない・・・。
頑張ったのに使えない。「MADE IN JAPAN」まで打刻したのに。

そこで、ショップオーナーさんの出番です。
原本の部品を切り離して、給油口に入るように加工していただきました。

0027.jpg0028.jpg

円筒部分を切り離します。


円盤でバネを抑え込むために、円筒部の高さがなくなり、その分、長くなったバネも短くしてしまいます。
そうしないと、バネが強くなりすぎて、スムーズにキャップを閉めることが出来ません。

0029.jpg

これくらい切れば大丈夫です。

組み付けてみます。
おぉ、ばっちり。

0030.jpg

これは使えそう。


タンクにつけていましょう。

0031.jpg0032.jpg

違和感なくつきました。


まるで、KV75用のタンクキャップみたいですね。
これで、ガソリンが漏れなければ、見た目も実用性もばっちりです。

0033.jpg

シェイク、シェイク、シェイク


まったく漏れません。
これで、ツーリングに行く準備はばっちりです。

あぁ。でもせっかく作った部品を無駄にしたくはない。
そのうち、あの部品が使えるように、タンクキャップのバネ部分も改造しようかなぁ。
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