Looking more closely at the photo in that link , and the locations of the mounting bolts - It must have taken a lot of time and effort to find sturdy bolt holes that would give good weight balance ( front / rear ) , and then to work out the stand geometry to match .... .... well done !
It would've needed at least a 15mm thick spacer, which would need to be laser cut, which I dont have access to. The shafts you mentioned would also need extending by that amount some how. Which would put the gear lever too far out and the water inlet and outlets would also be in the wrong positions. As the whole cover would be further away, the alternator wouldn't sit fully over the stator. This would need a 15mm thick spacer between the rotor and flywheel. You cannot space the flywheel out, due to the spragg and starter gear.
The bike will run on 1098 loom, ecu and dash. The cover is a single pickup, I think late 748 or 996. A 748 straight cut timing gear set has been fitted. With the cut outs on the gear. To get the timing correct for the crank position/ and pick up, a few options are available. 1, everything lines up... 2, broach a new key way in the gear. 3, weld up the gap in the teeth on the timing gear and machine the gap on the teeth where needed. 4, machine and weld a new boss on the alt cover in the correct position. 5, see if the map in the ecu can be altered, to compensate. Hnracing: 1, everything lines up...
A pic of a couple just drilled. Not deburred yet. Really tough material to drill. Solid carbide drills had to be used. Only the timing gear left, then dynamic balancing. The spragg gear has had bigger holes drilled. Had to step up the sizes.
Solid carbide drills Slot drills Rotabroach cutters Some of them are glass hard and didn't like being drilled. Wouldn't be keen on doing another set...
It is actually a 1098 timing gear. The 748 gear was drilled originally in a way that drilling and balancing would be an issue. It was easier to cut a new keyway in the 1098 one, to match the 748 timing position.
The bigger holes remove more material, to compensate for the extra material, removed in the teeth area.
They will need to be checked for balance. Unsure of the final figure but think just under a kilo lost. Plus over a kilo or so from the flywheel. Now for ally pulleys, light clutch, titanium idlers and tensioners...
