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Stock Pilot Head Saver? by hoser..
http://pilotodyssey.com/PO/viewtopic.php?f=71&t=3380		 Page 1 of 2
Author:  hoser [ Fri Aug 10, 2007 4:35 pm ]
Post subject:  Stock Pilot Head Saver? by hoser..
Honda no longer sells the stock heads so I thought about recycling some of the old stock heads that are damaged beyond repair.



First step is to make a holding tool to hold the stock head center.

I transfered the hole pattern to a 1/2" thick aluminum plate.

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Author:  hoser [ Fri Aug 10, 2007 4:36 pm ]
Post subject: 
Drill the holes, find center, drill that hole, use band saw to knock off the corners so its closer to round.

Drill and tap center hole to 14mm so it will thread into my other head holding tool.

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Author:  hoser [ Fri Aug 10, 2007 4:37 pm ]
Post subject: 
Stick it in the lathe to round off the corners

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Author:  hoser [ Fri Aug 10, 2007 4:39 pm ]
Post subject: 
Now with the head mounted to the HHHT (hoser head holding tool) start cutting out the old damaged head area so a replaceable dome can be installed in its place.

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Author:  hoser [ Fri Aug 10, 2007 4:39 pm ]
Post subject: 
Checking the size using one of my old pro design domes

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Author:  hoser [ Fri Aug 10, 2007 4:40 pm ]
Post subject: 
More to remove

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Author:  hoser [ Fri Aug 10, 2007 4:41 pm ]
Post subject: 
Boring out the spark plug hole

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Author:  hoser [ Fri Aug 10, 2007 4:41 pm ]
Post subject: 
Dome now fits

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Author:  hoser [ Fri Aug 10, 2007 4:42 pm ]
Post subject: 
With dome installed notice how much the old plug was offset?

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Author:  hoser [ Fri Aug 10, 2007 5:07 pm ]
Post subject: 
Anybody have a stock head that is junk, damaged by POOFKABOOM or stripped out spark plug hole?

I need a few test units to play with...
Author:  hoser [ Fri Aug 10, 2007 5:18 pm ]
Post subject: 
I was hoping to have these a no weld bolt in deal, just machine out the old dome area and press in new... but the top of the stock shell is so thin I don't think ONE O ring will seal or I would not want to chance it .

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Author:  hoser [ Fri Aug 10, 2007 5:19 pm ]
Post subject: 
Blue is where its thin red is where the TWO O rings are.

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Author:  hoser [ Fri Aug 10, 2007 5:21 pm ]
Post subject: 
I need to bore the head out to 1.5" or 2" then press in some solid stock, then weld it to the old head then drill and bore it out to the correct size so the dome will seal the coolant.

Right now I have a Tig but don't have aluminum filler rod or the proper gas for aluminum welding I will work on that this week.

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Author:  Stoneman [ Fri Aug 10, 2007 5:28 pm ]
Post subject: 
Nice work!
I will look thru my junk parts for a old head.
Looks like a good option since there are no more stock heads.
Author:  hoser [ Fri Aug 10, 2007 5:34 pm ]
Post subject: 
Stoneman wrote:
Nice work!
I will look thru my junk parts for a old head.
Looks like a good option since there are no more stock heads.


Thanks I will need a few to refine the process, hopefully you will get them back with a replaceable dome, I plan on having a pump gas and race gas dome.
Author:  TD [ Fri Aug 10, 2007 6:06 pm ]
Post subject: 
You can play with both of the ones you have from Me.

TD
Author:  hoser [ Fri Aug 10, 2007 7:17 pm ]
Post subject: 
Ok I machined out the hole in the head larger and made the weld in plug.

Now all I need is the welding stuff.

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Author:  hoser [ Fri Aug 10, 2007 7:21 pm ]
Post subject: 
TD wrote:
You can play with both of the ones you have from Me.

TD


Its your situation that finally got me off my ass to do this, I thought of doing this about 10 years ago when I first bought my Pilot, at the time it was faster and easier to just buy cool heads than to play this game, whats that saying nessessidy breeds invention?

I will weld this one up and see how the dome fits before hacking into yours lol


Each dome height might be custom depending on how much was cut off the height of each head in the past, I have an idea that might work to make standard domes work in any height head then we will have truly interchangeable domes.
Author:  Toyman [ Fri Aug 10, 2007 8:22 pm ]
Post subject:  Head
This is pretty cool!

No punn intended. He He.


I think it's always interesting when someone can take something that is basically worthless & make it into something of value once again.

Way to go Hoser!
Author:  bugeye59 [ Sat Aug 11, 2007 12:02 am ]
Post subject:  Re: Head
Toyman wrote:
This is pretty cool!

No punn intended. He He.


I think it's always interesting when someone can take something that is basically worthless & make it into something of value once again.

Way to go Hoser!


Hey Hoser! I'll be sending ya my wife for a Cool Head Mod! :shock: How much? :-) ...Baz
Author:  adnoh [ Sat Aug 11, 2007 9:52 am ]
Post subject: 
"H" nice work. Are you basing it off of the lrd cool head that once was made for the pilot. Shame the heads are no longer avalible. Maybe LRD or "H" will have a new batch made. Still have the LRD one for mock up.
Author:  hoser [ Sat Aug 11, 2007 10:31 am ]
Post subject: 
adnoh wrote:
"H" nice work. Are you basing it off of the lrd cool head that once was made for the pilot. Shame the heads are no longer avalible. Maybe LRD or "H" will have a new batch made. Still have the LRD one for mock up.


I still have the pro design cool head to model from, we need to find someone that wants to make them but as fill in work not run a huge batch unless someone wants to finance the big batch...

So anybody that knows machine shop owners the might be looking for some fill in work let me know.
Author:  TD [ Sat Aug 11, 2007 4:34 pm ]
Post subject: 
Hoser, I talked thursday to one who may be interested, I'll talk to him again monday,I'll do 10 or so if he can do them reasonable,
LRD is not interested unless its a run of at least 50 sold,

Very nice work on the stock head, is there a minimum thickness you could surface the head to to make them all accept the same dome, can the domes be built on a lathe or will they need to be CNC'd

TD
Author:  hoser [ Sat Aug 11, 2007 6:47 pm ]
Post subject: 
Ok an 2nd attempt, head number 2, this is the head that came with the 500cc big bore Pilot cylinder I bought years ago, its all hogged out and not right, nothing to lose here.

The first head I took to my buddy Pete he thought he had everything I needed to weld aluminum but I guess not, he said the fastest way to get it welded would be for him to take it to work and weld so I left it with him.


On this one I am going to try and make the insert bolt in, cut a O ring groove, install a O ring press it into the head then from the inside drill and tap holes so I can install small bolts from the inside, hopefully no welding required.

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Author:  hoser [ Sat Aug 11, 2007 6:48 pm ]
Post subject: 
The first step this time is to bore out the plug hole, how do you drill a hole when its a half a hole off? I used a mill cutter and went real slow .

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