Oakley Sunglasses Arm Repair

Broke one of the arms on my Oakley Sunglasses, so I made some alloy replacements.

Broken Arm.

Broken Arm.

Made one aluminium arm, came out pretty good, so I decided to do both!

Two arms.

Side view.

Front view.

Stihl MS660 Crankcase Repair

Someone had already tried to repair the crankcase, the pin for the chain-brake lever must've been loose, damaging crankcase, so they taped it out & installed an insert, with a screw used instead of the hardened pin.
The screw had broken off and the customer had attempted to drill it out...I decided to grind it out, build it back up with magnesium & re-drill for pin to be installed.

Damaged chain brake pin mount.

Also had very worn top cover mount.

I had ground out the insert & built back up with magnesium.

View from other side.

Built up before drilling.

Cover mount ground down, built back up, reshaped, drilled & re-taped.

Brake lever pin mount before drilling for pin.

Drilled and pin installed.

DIY Joplin Adjustable Seat Post Conversion

Got a Crank Brothers Joplin Adjustable Seatpost, that I wanted to convert to a remote setup and I didn't want to spend the money they were asking for the kit, so...I built it myself!

I bought the Joplin Seat Post off Trade Me for $50.00, so the first step, was to strip it and replace the worn parts, clean and reassemble.

Reassembled and tested...all set for modification to take DIY remote.

I wanted to make it an internal mechanism, so that dirt couldn't get in. I cut a slot into the front of the post, to accommodate the lever I was making.

Rear view of slot.

Small lever manufactured & ready for install.

Lever installed.

I had drilled a hole to allow for cable, making sure I aligned it with the lever.

Made up a boot out of an old tube, to keep out the mud.

Made up a remote trigger out of aluminium off-cuts & an adjuster off an old derailleur.

Installed...works perfectly.

Installed trigger.

Stihl MS660 Magnum Broken Crankshaft Replacement (warranty)

8 month old Stihl MS660 Magnum, with a broken crankshaft, to be replaced under warranty.

Crankshaft had broken off at the end of the clutch thread.

Removed tank, starter, muffler, clutch, oiler etc, ready to steam clean.

Cleaned, now dismantle further.

Fully dismantled & cleaned.

New gasket set & crankshaft under warranty.

The crankcase halves have been heated & bearings re-installed.

Crankshaft installed, along with new gasket & seals.

Right hand, top AV mount & tank bumper fitted, as well as oil tank reflector foil.

Fitting fuel tank, connecting impulse line & feeding stop switch wires through crankcase.

Installing AV mounts, oil pump, oil ring & hose.

Installing cylinder & piston.

Flywheel, coil & stop switch wires installed.

Chain brake & chain adjuster installed.

Oiler drive, clutch & covers installed.

Top cover, plug & manifold rings installed.

Carb, grommet, fuel line & throttle linkage installed. 

Filter base installed.

Finished.

Tuned ready for pick up.

DIY SRAM Shifter Mount

I purchased an SRAM X7 10 speed shifter for my Foes Fly, & I needed a mount, so instead of paying for one...

Marking out & cutting.

Cut out, ready for weld.

Clamped for welding.

Welded & ready for finishing/filing.

Finished & mounted.

Cost to make, materials...nothing, was from scrap aluminium, labour...about 2 hours, it would've been easier to buy, but then I wouldn't have a one off SRAM X7 Shifter Mount.