How to plug AIS using .45 casings? - Star Motorcycle Forums: Star Raider, V-Max, V-Star, Road-Star Forum
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post #1 of 33 (permalink) Old 12-20-2013, 05:12 PM Thread Starter
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How to plug AIS using .45 casings?

I stopped by my local gun store and had one of the guys give me two .45 casings. My question is do I just hammer them in and do I need to cut some of the casing off? These casings are pretty damn long at probably more than 1.5 inches long. So I don't want to hammer them in too far or too little and have an inch of brass sticking out from the engine. Thanks.
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post #2 of 33 (permalink) Old 12-20-2013, 06:28 PM Thread Starter
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I looked at the bottom of the ammo and realized it has .45 long written on it. This ammo is much longer than the regular .45 acp ammo so can I just cut my .45 long down to size?
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post #3 of 33 (permalink) Old 12-21-2013, 09:28 AM
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.45 ACP case is 0.473 inch dia., .45 Long (Colt) is 0.480 inch dia. These specs are industry standard for UNFIRED cases. If the cases you have are fired without being re-sized they will measure larger diameter.

I'm guessing it will be a little tighter, maybe just enough to collapse the case during installation?

Give it a try and see what happens

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post #4 of 33 (permalink) Old 12-21-2013, 11:10 AM
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I am doing the same thing for my AIS ports. Let´s stay in contact so we can check out what each other is doing and if it is succsessful. OK?

My feet on the pegs and lots of time to go where the road leads.
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post #5 of 33 (permalink) Old 12-21-2013, 11:12 AM
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45 shell casings for AIS

This psot is so that I get notified when one of you post again about this subject.

My feet on the pegs and lots of time to go where the road leads.
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post #6 of 33 (permalink) Old 12-21-2013, 12:26 PM Thread Starter
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I am doing the same thing for my AIS ports. Let´s stay in contact so we can check out what each other is doing and if it is succsessful. OK?
Do you mean you're also using the .45 long rounds to plug the ais holes?
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post #7 of 33 (permalink) Old 12-21-2013, 01:26 PM Thread Starter
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Well I tried getting the ais elbows out for a few minutes today before I had to go for work and it's definitely not easy. The vice grips ruined the thread on the slide hammer I was using so that trick isn't going to work, and I tried pulling and turning the elbow and it wouldn't budge even after freezing it with co2. All I can say is that I'm not looking forward to doing this again.
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post #8 of 33 (permalink) Old 12-21-2013, 02:48 PM
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You are farther along thatn me. I thought that the elbow would just slide out after taking off the nuts. Good luck with the back cylinder. It looks like it is harder to do bcause of the angle.
I also thought that I would put some alumaweld or somethiing like that to help the casings stay attached. What are you going to use, if anything.

My feet on the pegs and lots of time to go where the road leads.
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post #9 of 33 (permalink) Old 12-21-2013, 03:16 PM Thread Starter
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roblox84
You are farther along than me. I thought that the elbow would just slide out after taking off the nuts. Good luck with the back cylinder. It looks like it is harder to do because of the angle.
I also thought that I would put some alumaweld or something like that to help the casings stay attached. What are you going to use, if anything.
It definitely does not slide out, maybe you'll be lucky and yours will . I think taking both of them off will be equally as hard because like you said of the angle of the back cylinder and the front one has the frame right in front of the plug. I'm going to have to see if I can borrow a slide hammer from Autozone or Oreilys, at least that way I don't have to ruin more of my stuff, lol.

As far as gluing the casings in, i'm not sure if i'll use anything just yet. I'm going to see if they fit tightly in there but i've seen pictures where people put red loctite around the casing where it meets the head after they've plugged the hole. When I get home tonight i'll try one more time to freeze the elbows and just use pliers to pry it some more, if that doesn't work again i'll have to find another slide hammer. Keep me updated on your progress and i'll do the same.
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post #10 of 33 (permalink) Old 12-21-2013, 04:36 PM
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The ais elbows will come out. All you need if you don't have a slide hammer is a small pry bar/ long Handel screwdriver and a hammer. These are pressed into the ais ports. Just will take some time and beating to get out. The spent .45 shell casings will fit right in, I used a hammer and a punch and lightly tapped on the shell casings into the ports until it bottomed out. Then I used some jb weild on top of the shell casings just to make sure they won't come out. I just did this on my 650 v star custom.


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