3/19/2005

I built this flush kit clamp to get a handle on the flush kit for my Yamaha 
outboard.  I cracked the cartilage in my ribs for the second time recently 
because my boat is in a lift at a marina, and I can't reach the lower unit except
by stretching over the transom.  Needless to say, I'm not as young anymore.

This was made out of 3/4" 2024 aluminum.  The thumbscrews are stainless, and 
the threads in the aluminum are helicoiled.  Included are photos labelled

	FlushKitClamp00.jpg	drilling for mop handle thread
	FlushKitClamp01.jpg	boring for thread
	FlushKitClamp02.jpg	threading (I did this in reverse on back side)
	FlushKitClamp03.jpg	testing thread (took several tries)
	FlushKitClamp04.jpg	layout for threaded and clamp holes
	FlushKitClamp05.jpg	set up in V blocks
	FlushKitClamp06.jpg	drilling cross hole (to be split for clamp)
	FlushKitClamp07.jpg	drilling closeup
	FlushKitClamp08.jpg	shaper for flats after bandsaw to remove waste
	FlushKitClamp09.jpg	finished clamp
	FlushKitClamp10.jpg	another view of clamp

Hopefully, with a fiberglass extension handle and this clamp, I can position the
flush kit without busting anything else.

Regards,

Pete Keillor