Anybody here in the US with welding equipment?

[frankenduck]

I need help with a small project.

I have these aluminum oil filler caps on several of my K bikes.  I like them but I have to use that stupid little aluminum "key" thing to get them off.

I was thinking my life would be easier if I welded a 1/4" socket onto the top of it so that I could use it with a ratchet. Like so:

But I don't have any welding equipment.

Any volunteers? :dunno2:

[argent brick]

Why don't you weld the cap and the key together?

I am not a welder,but I think you have to weld aluminum a special way. It is called TIG welding.

[wmax351]

Why don't you weld the cap and the key together?

I am not a welder,but I think you have to weld aluminum a special way. It is called TIG welding.

Yeah. Flux core doesn't work. Has to be Mig or Tig. (Has inert gas, usually argon, around the welding zone.)

My friend will be getting a tig welder at some point in the near future. I will be helping him Megasquirt is '68 Camaro, and he will be welding some stuff for me.

[NCJ]

Not aware of any aluminum sockets available on the market; steel to alum. would of course be a no go as far as welding would be concerned.

You could possibly have a section of aluminum hex stock welded to the cap, which would allow the use of a socket to remove it (and lose the security feature) or mebbe have a slot milled in the working end of a socket, and (silver?) solder it in place on the removal key...my .02.

[wmax351]

Security on the oil filler? People steal oil now?

[Rick G]

Security on the oil filler? People steal oil now?

No but they will make them loose so the bike runs like crap and I do remember one guy here who had oil based valve grinding paste put in the oil. It did a real good job of wearing out the engine even though the filter caught most of it.

[lunchbox]

I'm happy to help with sorting out a solution. I have access to MIG, TIG, Oxy/Acy equipment. PM sent.

[frankenduck]

Security on the oil filler? People steal oil now?

I use them because I prefer them to the plastic BMW ones, not because I'm afraid somenbody's going to steal my oil. :laugh  I picked them up cheap on Fleabay when the maker was dumping old stock after they stopped making them.

[Photog]

Drill a hole in the center and put a bolt in it. If the cap is thick enough you could thread the hole, or else just use a nut. Locktight and some rtv silicone to finish things off.
Another possibility would be to epoxy the key onto the cap.
Welding a piece of aluminum hex bar would do what you're looking to do, but the cap maybe too small and thin for welding. Doing it would probably require someone really good at welding.
OR (just thought of this), get some hex bar (www.onlinemetals.com, is a good place), drill the cap and the bar, thread the bar, screw them together from the inside, use epoxy instead of locktight on the threads.

There are also some solders for using on aluminum, but in general solder and aluminum don't get along with each other well.

[frankenduck]

I'm happy to help with sorting out a solution. I have access to MIG, TIG, Oxy/Acy equipment. PM sent.

Cool, I'll call you later today.

[frankenduck]

Well, finally resolved this today.  The welding obviously wasn't going to work but when I talked to lunchbox on the phone he suggested cutting a notch in old socket.  I put some notches in the sides too until I had holes on the sides and then ran a couple of strands of brass wire over the key and out the holes to hold it in place.  It's not the purdiest contraption but at least now getting my fancy aluminum oil caps on and off is easier since I can use a 1/4" ratchet or a bit driver. :2thumbup:

[lunchbox]

Did you try the JB weld or Quiksteel first or go straight to the wire? I like the wire, quick and simple.

Glad I could help.

[frankenduck]

LB: Yes, your idea worked out great. Thanks. :2thumbup:

I went straight to the wire because in my experience JB Weld and similar products are pretty good but I wasn't 100% sure  that it would hold up in the long term.  However, once I had it wired up like that I filled the socket part with epoxy just to keep it positioned correctly.

I used it yesterday to top off my K75.  Works like a charm.