Case Matching: Puch ZA50

I did myself a little case matching today on my ZA50 today.

This is my first attempt at case matching. I figured I would

share my experience.

I used a Dremel tool with high speed cutter attachments #115

for the initial cuts and a #117 to finish the tight corners. These

attachments are meant to be used at high speed on the Dremel.

Slow speed will cause them to jump and lead to less accurate

results. There is no need to buy the expensive carbide bits.

They are expensive and meant for harder metals. Aluminum is

soft as cheese.

I used a bench vice and MDF board shims to secure the engine.

I taped down my 64cc Polini gasket to the engine case with electrical

tape. I traced the inside opening of the gasket with a Sharpie marker.

The black areas represent material I will need to remove with the

Dremel tool. I start with the #115 bit to make my first cuts. I angle the

bit at 45 degrees to the flat surface of the top of the case. I follow up

with the #117 bit to fit in the tighter corners and smooth out my first

cuts. Be sure to brace your body against a bench or table and steady

your Dremel with both hands.

I placed the gasket on the case after cutting away at the case for

about 15 min. I'm really pleased with the results.

You can continue to smooth out your cuts with a small fine hand

file and some medium grit sand paper. Here's a look into the case.

I went about 1/2" into the case with my cuts. I will finish smoothing

out the cuts after I get the engine back to Brooklyn. This is a close

up of the stator plate side transfer.

This is a close up of the transmission side transfer.

I've got the cases soaking now in a pail full of degreaser

overnight. Tomorrow I will wet sand and polished the cases

with some Mother's Mag & Aluminum Polish to make this

thing super shiny.