Hello fellow super 9 junkies. It's your local forum Bigfoot here with a quick DIY. Let me preface by saying yes I'm aware the design could have been more creative and better looking, but that wasnt really the goal for this exercise. I wanted to perform this mod using only NON-specialized tools that are common to most everyday mechanics/hobbiest's. With that said I will include alternative tools that could be used if you are so fortunate to have access to. The list of materials used in this demonstration are:
1. Stock clutch bell
2. Bench vise (not required)
3. Angle grinder w/cutting wheel (Dremmel can be used, more on that later)
4. Dremmel style rotary tool with various sanding drums, Dimond ginding bits, Dimond cutting discs
5. JB weld epoxy (Real welder if available)
6. High temp paint of your choosing (I used Ford Engine grey 500°)
7. Socket set, screw drivers, pliers, etc.. as needed to take CVT cover & clutch bell on/off.
8. Fine tip sharpie pen
9. Small strait edge or compass
10. Safety glasses
Let us assume the the CVT cover and clutch bell have already been removed. First thoroughly clean the clutch bell to remove any gime/grease. Next lay out a design on the clutch bell using your sharpie pen and appropriate measuring devices. Once the design has be made and will not weaken the structural integrity of the bell, place the clutch bell in a bench vise with any means available to ensure the edges/face doesn't get scored up. Once secured in the vise and you have proper eye protection, use your angle grinder w/cutting wheel to make your rough cuts. An air operated riciprocating saw would be ideal here. Once your rough cuts are made the tedious work begins. Since the grinding wheel I used was too large at 4.5in dia, the are several over cuts in places I don't want them to be. This is where the JB weld (or real welder come into play). I started on the hub area first as I knew there wouldn't be any more cutting or shaping to this area. Using the JB weld epoxy, fill in the over cuts. Don't worry about excess epoxy as it will be sanded flush later. Once the epoxy has set up for 10 mins or so, you can now work with the piece without making a mess. The next step is by and far the most important and time consuming. Using your dremmel, begin removing the areas of metal that were not first removed during the rough cut process. I alternated between a course grit sanding drum, corse grit Dimond grinder bit, and a Dimond cutting/grinding wheel. As it turns out the sanding drum was most effective for removing larger amounts of material while also providing a smooth surface free of snags and bur's that can really hurt your little digits. After several hours, you should be done grinding/sanding and ready to finish up. Once the metal removal is done you can now fill all the other over cuts from the first rough cut, using your JB weld. Once the epoxy has set 10-15 mins, use your dremmel with Dimond cutting disc (for edges/corners) & sanding drums (for larger/flat surfaces) and remove any excess epoxy left over from filling. After you have removed all the extra epoxy and are satisfied with the end result, you are now ready to clean the clutch bell and thoroughly dry the part before painting. Using several light coats of paint instead of one heavy coat, cover the out side surface of the clutch bell entirely. Try not to get paint directly into the spine area of the hub. Once the paint is dry you are ready to reinstall everything and enjoy. I hope this helps inspire others and erasure that there are alternatives to buying aftermarket parts. Now for those lucky enough to have shops woth great tools, I recommend using a die grinder for excess metal removal, air operated riciprocating saw for design cutting, mig or tig welder for and filling that may occur, a 90° grinder with sanding/scotchbrite pad for finishing and de burring. I orignally began this mod using only my dremmel and dimond cutting discs. The metal on the bell was too much of an adversary and took over an hour to make one cut completly through. Needless to say, that there was a better way (abiet not as clean and percise.. enter angle grinder lol) Thanks for reading.
