On Wed, 29 Jun 2011 14:07:20 -0700, Gunner Asch wrote:
On Wed, 29 Jun 2011 14:29:56 +0000 (UTC), James Waldby wrote:

http://www.samstagsales.com/whitworth_table.htm has been mentioned
already. What sizes of sockets do you actually need for the Royal
Enfield? Pick out some size frequently used on the bike, eg 5/16 W for
3/8" bolt, with heads 0.600" (15.24mm) flat-to-flat. An SAE 5/8" will
be too loose by some amount, let's say 0.025" (.635mm). Put a 5/8"
socket into an index on a mill, and make 3 cuts with a thin slitting
blade so that the socket size can be squeezed down .025" with a ring
clamp (hose clamp). Check fit on some bolts, if ok tig tack, take off
clamp, recheck fit, if ok weld up the three cuts. Then turn smooth in
lathe, polish, chrome plate, etc.

So this is somehow better..assuming it doesnt crack..then simply buying
a socket?

In R.C.M, right. BTW, what head sizes actually appear on the bike?

Now if that socket cracks while squeezing it....Id have to weld that up
too. So pretty soon that socket is looking like hammered **** and it
may or may not crack if I put some Ommph! on the handle.

No, if it cracks when clamped, you picked the wrong socket size
to start out, so just pitch it and start over.

Sigh..I guess I just dont have the pioneer spirit..the sense of
adventure...the ..well..I guess Im just a staid old fart who wants to
work on the bike..not build new tools before starting on the bike.

But Thanks! I definitely keep that in mind! Im curious though..any
idea of what RC a good socket has.or a good box end? Just so I know how
many slitting saw blades to stock up on.

http://www.mountztorque.com/learning-center/guide/selecting-proper-socket-your-power-tool
lists HRC43-45 for impact sockets and HRC47-49 for some other kinds.

And the way to modify a box end would be to cut out a section..heat
it red hot..hammer it over a Whitworth bolt head until it fits..kinda
sorta..then weld it closed..then machine/file/grind all the sniggly
little bits that dont quite line up? Cool! I'll definitely keep
that in mind. And of course..open end wrenches..that would be easy!

Cutting out one section of a box end (with 2 cuts) isn't going to
work because that will leave several wrong-length flats. If you
make 3 cuts (at corners 1,3,5) any exact length of side can be made
easily by grinding the pieces. However, unlike in the socket method,
there might not be a good way to hold the three pieces for welding.

If you have a spare deep wall impact socket sitting around, and a good
slitting saw, you could make the three cuts, decrease the socket size
a little via ring clamp, and try it out, without doing any welding.
Note, with deep wall sockets you can make the 3 cuts longer, so that
flex angle is smaller. Plus if you weld it, you get more welding
practice on the longer cuts.

--
jiw