Installing emulators and springs: Difference between revisions

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Step 14: De-burr and chamfer the holes, inside and out. ~~Those drill~~ holes ~~will have~~ to be ~~cleaned up~~. ~~Chamfering~~ the holes ~~should increase flow~~. ~~Racetech instructs you~~ to do this ~~in the directions~~. ~~Use~~ a rotary tool (dremel) to ~~smooth~~ the ~~holes~~. ~~Get one of~~ the ~~narrow sanding bits~~ for ~~your~~ dremel. ~~Then~~ use some sandpaper to smooth things out further~~. You could also probably use a circular file with good results~~.

Step 14: De-burr and chamfer the holes, inside and out. Racetech instructs you to do this in the directions. When you chamfer the holes, you are essentially getting rid of the sharp 90-degree corners where you drilled the hole and replacing the straight line with a beveled edge. This makes the fluid (fork oil) flow better through the holes, which is why the extra holes are there in the first place.

One way to safely chamfer the hole would be to use a small, circular file. With the file held at a 45-degree angle to the rod, file evenly around the holes until the outside edge is beveled. Repeat for the inside edge. You'll need a file that has a smaller diameter than 5/16" (the diameter of the hole) in order to do this effectively.

Another way would be to use a rotary tool (dremel) with a sanding bit. Do basically the same process as above. The dremel makes for light work, but it is much easier to make a mistake by removing too much material. It is also much easier to have an accident when chamfering the inner surface, since the tool is mostly inside the damper rod, and if/when it catches the wrong edge the tool can fling about violently. A drill bit on the dremel is most definitely the '''wrong''' tool for the job.

Arguably the best way to make a beautiful chamfer for the outer surface is to use a [http://en.wikipedia.org/wiki/Countersink countersink drill bit] at the same time as the first hole is drilled. This will make a perfect chamfer on the outside edge. The inside edge will still require a tool like a dremel or a file.

After chamfering, use some sandpaper to smooth things out further.

Step 15: Clean up the modified damper rods. There will be lots of metal shavings. Spray brake cleaner in and out to clean things up.

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-Step 14: De-burr and chamfer the holes, inside and out. Those drill holes will have to be cleaned up. Chamfering the holes should increase flow. Racetech instructs you to do this in the directions. Use a rotary tool (dremel) to smooth the holes. Get one of the narrow sanding bits for your dremel. Then use some sandpaper to smooth things out further. You could also probably use a circular file with good results.
+Step 14: De-burr and chamfer the holes, inside and out. Racetech instructs you to do this in the directions. When you chamfer the holes, you are essentially getting rid of the sharp 90-degree corners where you drilled the hole and replacing the straight line with a beveled edge. This makes the fluid (fork oil) flow better through the holes, which is why the extra holes are there in the first place.
+One way to safely chamfer the hole would be to use a small, circular file. With the file held at a 45-degree angle to the rod, file evenly around the holes until the outside edge is beveled. Repeat for the inside edge. You'll need a file that has a smaller diameter than 5/16" (the diameter of the hole) in order to do this effectively.
+Another way would be to use a rotary tool (dremel) with a sanding bit. Do basically the same process as above. The dremel makes for light work, but it is much easier to make a mistake by removing too much material. It is also much easier to have an accident when chamfering the inner surface, since the tool is mostly inside the damper rod, and if/when it catches the wrong edge the tool can fling about violently. A drill bit on the dremel is most definitely the '''wrong''' tool for the job.
+Arguably the best way to make a beautiful chamfer for the outer surface is to use a [http://en.wikipedia.org/wiki/Countersink countersink drill bit] at the same time as the first hole is drilled. This will make a perfect chamfer on the outside edge. The inside edge will still require a tool like a dremel or a file.
+After chamfering, use some sandpaper to smooth things out further.
 Step 15: Clean up the modified damper rods. There will be lots of metal shavings. Spray brake cleaner in and out to clean things up.