Laser cut gaskets for the stator cover (5th gen)

Discussion in '5th Generation 1998-2001' started by connah250r, Oct 3, 2023.

  1. connah250r

    connah250r New Member

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    Hey all.
    For those who haven't seen my thread on my struggles with my stator, I laser cut my own gasket for the stator cover on my 99. I believe in open-source, so I thought I'd share the files with y'all, free of charge. Linked here is a Google Drive folder with the gasket in both .ai (vector) format and .lbrn2 for those who use LightBurn. https://drive.google.com/drive/folders/1GIyjXeez5uceWoJnnzxYZEwzmSXiJbk8?usp=sharing
    I made this gasket by taking a picture of a gasket off eBay, throwing it into Scan2CAD to model the shape, then tweaking the placement and scaling in Adobe Illustrator.
    IMG_4119.jpg
    The picture you see is an earlier gasket I cut with a fiber sheet on my Atomstack S10 Pro. (The newer gaskets attached have a much better fit) The gasket that ended up fixing my leak on the bike was made from rubber, but I had a tough time cutting through the rubber with the laser, so instead I made a single pass engraving on the rubber, then cut the outline out with a razor knife. There are more powerful lasers out there that will cut through rubber, but not my 50W S10. YMMV. But, if you own/have access to a laser cutter, I hope these files serve you well in letting you choose what material and thickness you want your gasket made out of.

    THESE FILES ARE PROVIDED AS-IS WITH NO IMPLIED WARRANTY OR RESPONSIBILITY. PLEASE EXERCISE CAUTION WHEN OPERATING A LASER CUTTER OR CNC MACHINE.
     
    Last edited: Oct 3, 2023


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  2. connah250r

    connah250r New Member

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    Update for future reference- dont use a rubber gasket, it'll end up breaking
    I'm using a Fel-Pro 3045 gasket sheet for cutting now, and it seals great. I'm still leaking oil out of 2 cracks in my stator cover. Preparing to sandblast and JB weld tonight if I have time, and hopefully that'll fix it. But, since switching to the fel-pro sheets I haven't had any gasket leaking issues. (Plus, the Fel-Pro can be fully cut with a laser, no razor required)

    Edit- FelPro works great, I sandblasted the cover a while ago and JB Welded the inside, and all works great
     
    Last edited: Jan 28, 2025


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