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Old 01-03-2007, 12:41 AM   #1
crimescene
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Default Splitting Rockers, step by step

Hi Guys,

Here is the step-by-step sequence I did on splitting the rockers on my ironhead. Weyland was the inspiration for this method of cutting them, and in my opinion it is the best looking result. Just splitting them will leave you with mis-matched rockers (one square and one rounded) on the Ironhead.

Here is where I started. I sketched out some shapes first, until I liked the basic look.

See how they are square on one side and rounded on the other? That is the key thing to deal with. The brass nut is from Weyland, it screws into the end of the rocker shaft.




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Old 01-03-2007, 12:42 AM   #2
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Default Re: Splitting Rockers, step by step

I used a little pattern tool to pick up the shape on the curved side and transfer it over to the square side

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Old 01-03-2007, 12:44 AM   #3
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Default Re: Splitting Rockers, step by step

OK, time to get serious. Fire up the mighty Do-All and whack off the corners.

Note that I made the cut short of the hole where the rocker shaft come out. I wanted to make sure I had enough room to weld and grind without getting into the holes. When I'm done I want this side to taper down _almost_ to the shaft hole to match the other side.

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Old 01-03-2007, 12:45 AM   #4
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Default Re: Splitting Rockers, step by step

We'll need to do something about that hole or there will be a big puddle on the floor...

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Old 01-03-2007, 12:47 AM   #5
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Default Re: Splitting Rockers, step by step

I cut out the "bridge" between the two sides. There is an oil port on the square side that feeds both shafts (through this bridge part). We'll need to plumb both rockers later.

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Old 01-03-2007, 12:50 AM   #6
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Default Re: Splitting Rockers, step by step

I attached the middle area with a no-load grinding disc (specifically for aluminum). I wanted to round it over and get a nice flow going.

Use the flat of the disc, not the edge, and it is really controllable.

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Old 01-03-2007, 12:52 AM   #7
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Default Re: Splitting Rockers, step by step

If you compare this with the shot of the rockers boxes just after they were cut apart you can see how much material I hogged off. It goes quickly enough.

I wanted to rough these in because I have to weld up the oil galley that runs all the way through the covers.

Once I hogged the buld of the material off I used a counter sink to bevel the hole and welded it up. Then I dressed it down a bit further with the belt sander.

The belt sander is one of my favorite tools. It can hog off metal, or do a really fine fine finish.


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Old 01-03-2007, 12:53 AM   #8
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Default Re: Splitting Rockers, step by step

Here is the middle section roughed in. Now we need to close up that ugly hole.

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Old 01-03-2007, 12:54 AM   #9
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Default Re: Splitting Rockers, step by step

And we need to weld up the oil passage too.

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Old 01-03-2007, 12:55 AM   #10
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Default Re: Splitting Rockers, step by step

I did the "dirty finger" template thing, and started making a little plug to fill the hole.

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Old 01-03-2007, 12:56 AM   #11
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Default Re: Splitting Rockers, step by step

Here is the part fit into place.

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Old 01-03-2007, 12:58 AM   #12
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Default Re: Splitting Rockers, step by step

I used a junk rocker shaft to try to control distortion, we will be making this really, really hot for a while

I welded around the seam, then build up the surface with several passes so that I had some material to shape.

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Old 01-03-2007, 12:59 AM   #13
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Default Re: Splitting Rockers, step by step

Pretty much done, I checked the rockers side-to-side with a template to make sure they matched. I took them up to 320 on a D/A sander to get everything nice and smooth.

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Old 01-03-2007, 01:00 AM   #14
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Default Re: Splitting Rockers, step by step

With the brass nutz from Weyland mocked up (no shafts)

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Old 01-03-2007, 01:08 AM   #15
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Default Re: Splitting Rockers, step by step

Add chrome, polishing the nutz, Weyland's hex covers on the pushrod tubes and some assembly and you get...allowing for a poor photographer

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Old 01-03-2007, 01:17 AM   #16
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Default Re: Splitting Rockers, step by step

I found a better shot of the finished rockers with the shiny stuff. applied...

Two thumbs up for Weyland, who provided the inspiration for this, I just supplied the perspiration.


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Last edited by crimescene; 01-03-2007 at 01:20 AM.
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Old 01-03-2007, 01:04 AM   #17
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Default Re: Splitting Rockers, step by step

You get that box yet? I'm getting worried...

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Old 01-03-2007, 01:10 AM   #18
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Default Re: Splitting Rockers, step by step

Quote:
Originally Posted by Weyland
You get that box yet? I'm getting worried...

Weyland
Yes...I actually meant to call today. I got "behinder" over the holidays. The (BRASS) mag cap is awsome. I might to get to actually work on my bike tomorrow. We'll see.
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Old 01-03-2007, 01:14 AM   #19
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Default Re: Splitting Rockers, step by step

Really amazing stuff! Thanks for the class! Now give us some more...
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Old 01-03-2007, 02:19 AM   #20
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Default Re: Splitting Rockers, step by step

any close ups of how you plumbed for oil? looks really nice btw
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