Gasket made today, but I have not cut away the excess OD yet.
I bolted the gasket material to a piece of 1/4″ fiber board, then
screwed that to a chunk of 2×4″.
This allowed me to mount it in the milling machine vise.
I had a 2-1/8″ hole saw (the cylinder diameter) so I mounted it
in the milling machine. It had a fair amount of “run out”, so
I was afraid it was going to cut over-sized, but it did not.
After tracing all the holes onto the gasket material using the old gasket,
I found center of the cylinder holes with a compass,
and marked a tiny hole with an ice pick.
I used a tiny pin in the milling machine to align up the center of the hole
to be cut out.
All the holes cut out fairly good, with only some “fuzzy” to clean out
of the holes.
I then used some different size end mills to plunge cut the
holes for the water passages. It took a while, but faster
than waiting for a new gasket to arrive in the mail from
the Minneapolis Champion headquarters.
For good luck, I used Aviation Permatex on both sides of the gasket.
The gasket is torqued down, and tomorrow I may cut off the excess OD.
Prepare to be boarded!