Do It Yourself Pilot CDI Build Up Instructions Continued By Bill Keefe

21. BE careful not to damage the plug. Cut slowly up to the edge, but not all the way through - as shown.



22. OK, now we are ready to finish the cut all the way up to the plug.



23. Carefully finish the cut without damaging the plug. You can use a knife for this or the 
grinder whatever you feel confident with. 



24. Now the edges are cut remove the four pieces of plastic from the edges in the same manner 
you removed the bottom. 






27. You will end up with this if your cutting turned out OK. 



28. CDI box will all the plastic removed. Retaining clip is still bent. 




29. I straightened out the bent plastic retaining clip as best I could. It looks better anyway. 



30. Time to start cutting away potting compound. Get out your favorite knives. 
**** BE Careful  - Do not cut yourself !!! ***



31. The case I use is the same width as the factory one. Some trimming will be necessary 
for it to fit, and have enough room for new compound.



32. I start by cutting all the way around the top perimeter at a 45 degree angle. Not to deep. 
This give the compound a place to flow as the box is being poured full. 



33. Be careful around the plug. Cut using easy pressure and don't get carried away. 
If at any point you feel like you have hit something solid, stop and back up. 
Do not cut into any components or you may damage the unit. You will feel it if you run 
into something.



34. Upper cut almost finished. 



35. Upper perimeter cut finished. 





37. Now were ready to start the bottom perimeter cut. 



38. Same thing. I cut at a 45 degree angle until I feel the circuit board and then 
just trim right down the side of it.
 


39. Bottom edge of circuit board exposed all the way around. 



40. Now I cut a notch out all four corners like shown here. I do this so when the compound dries 
it is like a wedge locking the unit into the case. 



41. Now one side needs to be trimmed so it will fit onto the case. 
Look at the unit and see which side has the most compound hanging over the edge 
of the circuit board. Make the cut 90 degrees (perpendicular) to the board. Nothing 
hangs out past the board so as long as the cut is 90 degrees you will not hit anything. 



42. Finished cut. Note: On some CDI's the compound is thicker on the other side, 
it just depends on how it dried at the factory. Like I said, cut the thick side. 



43. Test fit unit to the new case. If it fits your good to go. If not trim some more until it does. 

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