Make Copper Head gaskets

Wrench

Active Member
Joined
Nov 14, 2018
Messages
147
Howzit Everyone,
Making your own Copper Head Gaskets saves a lot of money$ and now you can match the combustion chamber exact.
Cutting and drilling thin copper sheet takes some thought and skill. I'll explain in order what works for me and the basic tools I use.
I use .016 th" thick copper sheet and sandwich the copper sheet between two pieces of wood. I make 3 at a time.
Using an old gasket line it up and mark center of cylinder on wood. Drill a pilot hole.
Using the correct size hole saw drill the cylinder hole. I use 2 1/4"
Using an old gasket line it up with the cylinder hole just drilled and trace valve area on wood.
Drill out valve area with correct size hole saw. Only get close to the traced line. I use 1 1/8"
Remove copper sheet from the wood. Using an old gasket line it up with copper sheet.
Mark bolt holes and center punch them. Then drill bolt holes in copper sheet.
The best way I've found to do this is to drill two bolt holes first, Front and Rear. I bolt the head and copper sheet to one piece of wood.
Using the head bolt holes as a guide I drill out the rest of the bolt holes in the copper sheet.
Start with the smallest drill bit and work your way up to bolt hole size. Don't press too hard let the drill bit do the work.
Now smear a light coat of grease on the head. Make a pattern by Lining up the copper sheet to the head and make an imprint of the combustion chamber or trace an old gasket. Etch the combustion chamber pattern on the copper sheet with a scratch awe.
Use the Dremel tool with a thin cut off wheel. Cut to line as close as possible without cutting line.
Finish combustion chamber pattern with Dremel tools metal grinding barrel, grinding stone and sanding barrel.
Now make the perimeter pattern. Trace an old gasket perimeter or make an imprint of cylinder deck perimeter on the copper sheet.
Using Dremel tool with a thin cut off wheel cut out the pattern. Clean up edges with Sanding Disc .
Sand with an electric palm sander or sand by hand all burrs with 80 or 120 then 220 sandpaper. The new copper gasket is finished.
I buy my copper sheet from Ace Hardware .016" x 6" x 12" for $12.99 a sheet makes 3 gaskets.
After ya make one or two you'll get the hang of it.
No pictures of making copper gaskets yet. Over the years I've made a whole bunch to match the different heads I have.
I hope this info can help someone
ALOHA Wrench
 

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Jobe D

New Member
Joined
Aug 29, 2019
Messages
9
Howzit Everyone,
Making your own Copper Head Gaskets saves a lot of money$ and now you can match the combustion chamber exact.
Cutting and drilling thin copper sheet takes some thought and skill. I'll explain in order what works for me and the basic tools I use.
I use .016 th" thick copper sheet and sandwich (clamp) the copper sheet between two pieces of 1/2" wood. I make 3 at a time.
Using an old gasket and the correct size hole saw line it up mark center of cylinder on wood and drill the cylinder hole.
Using an old gasket line it up with the cylinder hole just drilled and trace the valve area on the wood.
Drill out valve area with correct hole saw. Only get close to the traced line.
Remove the copper sheet from the wood. Using an old gasket line it up with the copper sheet.
Mark the bolt holes and center punch them. Then drill the bolt holes in the copper sheet.
The best way I've found to do this is to drill two bolt holes first, Front and Rear. I bolt the head and copper sheet to one piece of wood.
Using the head bolt holes as a guide I drill out the rest of the bolt holes in the copper sheet.
Start with the smallest drill bit and work your way up to bolt hole size.
Now smear a light coat of grease on the head. Make a pattern by Lining up the copper sheet to the head and make an imprint of the combustion chamber or trace an old gasket. Etch the combustion chamber pattern on the copper sheet with a scratch awe.
Use the Dremel tool with a thin cut off wheel. Cut to line as close as possible without cutting line.
Finish combustion chamber pattern with Dremel tools metal grinding barrel, grinding stone and sanding barrel.
Now make the perimeter pattern. Trace an old gaskets perimeter or make an imprint of cylinder deck perimeter on copper sheet.
Using Dremel tool with a thin cut off wheel cut out the pattern. Clean up edges with sanding disc . Sand by hand all burrs with 220 sandpaper. The new copper gasket is finished.
I buy my copper sheet from Ace Hardware .016" x 6" x 12" for $12.99 a sheet makes 3 gaskets.
After ya make one or two you'll get the hang of it.
No pictures of making copper gaskets. Over the years I've made a whole bunch to match the different heads I have.
I hope this info can help someone
ALOHA Wrench
My dad taught me that when I was a youngster. I'mthinking not many know how anymore. Darn good gaskets. Nice you're passing down some old school tricks. Thanks.
 

Wrench

Active Member
Joined
Nov 14, 2018
Messages
147
Howzit Everyone,
A couple of friends talked me into helping them make some Copper Head Gaskets.
I ordered this roll of 26 gauge copper sheet .016" x 6" x 120" $69.95 + free shipping
This roll will make 30 Whizzer Head Gaskets.
That's about $2.25 a gasket
ALOHA Wrench
 

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Wrench

Active Member
Joined
Nov 14, 2018
Messages
147
Howzit Everyone,
Started to make Copper Head Gaskets.
I took step by step pictures.
I explained steps in Post #1
A lot of pictures gonna take 3 Posts.
ALOHA Wrench
 

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Wrench

Active Member
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Nov 14, 2018
Messages
147
Making Copper Head Gaskets.
 

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Wrench

Active Member
Joined
Nov 14, 2018
Messages
147
Here's a TIP
To insure the bolt holes to be drilled in the Copper Head Gasket are perfectly centered.
Select a 1/4" drive deep well socket that will snugly fit the head bolt hole.
Select a drill bit that will snugly fit the deep well socket.
This will insure the guide hole for the hole to be drilled is perfectly centered.
Remember, start with a small drill bit first and work your way up to bolt hole size.
Pictures will explain everything.
 

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Wrench

Active Member
Joined
Nov 14, 2018
Messages
147
Pictures of finishing up the 9 Copper Head Gaskets I started making in Post #4
The first Gasket I made I will use as a pattern.
See how nice they all turned out.

If ya don't have a Laser C&C Machine.
Ya can still do it by Hand

ALOHA Wrench
 

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Wrench

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Nov 14, 2018
Messages
147
In Post #3 My 2 friends wanted me to HELP them make some Copper Head Gaskets.
Well as it turns out, my friends wanted me to MAKE them some Copper Head Gaskets.
I made 30 Gaskets from that 10' roll of copper I bought in Post #3
I sold each of my friends 6 Gaskets for $100

I Sold 12 Gaskets for $200
The Copper + Tax was $75
I made $125 and I have 18 Gaskets left for myself.
I think I have enough Block Head Gaskets to last me a while.

Pictures of my 18 Gaskets
Once again see how nice they all turned out.
ALOHA Wrench
 

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