Laser Cutting Saturno Gaskets

[mikewallis]

I recently needed a LH engine cover gasket for my 350 Saturno. Not having a gasket set to hand I ended up scanning the engine cover to create a laser file. Later on I bought a complete Athena gasket set for my 350 and scanned and created Lightburn files of the remaining gaskets with the view to posting them to the Gilera Owners groups.

Gilera.jpg

The archive (see below) contains three Lightburn 2 files that can be used to create the paper gaskets for the Gilera Saturno using a laser engraver.

I have also included three screen shots of the files in Lightburn for reference.

Before cutting a gasket be aware of the following
- Adjust the power & speed to suit your laser (defaults are for my 10w diode laser)
- Use a cutting bed such as a honeycomb base for a clean cut
- Use air assist for a clean cut
- Hold the paper down outside the cutting area with small magnets (if base is steel)
- Use a steam iron to flatten the gasket paper if needed

Comments, feedback or suggested improvements can be posted here.
Happy Cutting!

Mike

[Joachim]

what a great idea
I hope you are used in doing such things so it takes not much time.
Otherwise i feel guilty while staeling your life time
Im selling this gaskets since years
First time i cut them with the foil cutting plotter at work.
Rather awkward.
This year i tried to use my new 10W LED Laser
Much easier.
I cut 15m gasket paper in raw piece and then cut about 320 gaskets, 160 each side
200 of them went to italy
I sell them to the costs of myself, 1Euro each.

Ironing... good idea.
I will try this next time
After the raw cut i stored the gasket paper on a plane surface with a weight on.
It sometimes takes 1 or 2 years until i do the next bunch, so it's half the way plane
I use a honeycomb plate under the paper and 3d printed clamps for adjustig and fixing the paper
Mass production

ciao Joachim

PS a few weeks ago i did the sealing for the 125ccm motor case. I haven't tested it 'till now
I should order some gasket paper to give it a try

[mikewallis]

It only took me a couple of hours to make up these templates after scanning.

I've done a lot of graphic design over the years including for laser cutting and engraving so it wasn't a difficult task.

The various Gilera owners groups have been very helpful to me during my Saturno ownership so I wanted to give something back.

Cheers!
Mike

[Joachim]