DIY billet clutch cover

[steliost]

The clutch cover on the EC250 started weeping from where it was already welded and I put some Mannol cold steel epoxy there but it did not convince me enough... On the search for a new cover I found out they are pretty scarce and expensive.

So I decided I would try to make one out of a fat slice of aluminum on the lathe and mill. Fun! A bit less than 25 euros of material and 3-4 hours of work, with breaks, and here we are. I had to cut off the excess material around the flange with a handheld grinder since my milling machine is quite old and does not support such intricate cuts, and that was the most time consuming and boring part of the operation. Not much fun. aluminum dust all over the place.

I left 1mm more room on the inside for the clutch and went about double the thickness on the face for extra durability, the stock is only 4 mm and caves in like that! I know it's a bit rough around the edges and heavier but ehh... saved us a 100 euros at least and the hassle of searching all around the interwebs.