How to Make a Gasket

Well, my SR500 has been getting more wrenching than riding since I bought it a couple of months ago. It's titled, tagged and insured, but I've been spending time just going over it and getting caught up on maintenance. The most recent thing was an oil change. I wanted to do it right, so I removed the downtube strainer and the belly pan so I could clean the screen down there in the pan. (Don't worry about the metal shavings. I'm sure that's nothing to worry about.)

When I removed the small oil "pan", the gasket was destroyed in the process. So I set into making a new one. I tried three different unsuccessful methods before finally calling John and asking him how it's done. He told me to use a manila envelope and to use a tiny hammer to tap out a template. I thought he was talking about a sort of cookie cutter method where I would be hammering the metal part trying to make an indentation in the envelope. Luckily he realized I misunderstood him and he clarified that I would be rubbing the envelope and NOT whacking away at the metal piece. So, I followed his instructions and it was easier than I expected. I used the ball part of the hammer and got a very distinct line I could trace with an exacto knife. And the "rubbing" part took less than 3 minutes. See below:


I was very happy with the results. From there, all I had to do was cut out the tracing. John suggested that I use the Hylomar between the gasket and the belly pan. But he said I should use a very small amount of anti-seize between the gasket and the engine. That way I could likely use that same gasket the next time I take the belly pan off. Instructions were followed to the letter. It's days like today - when parts just go together like butter - that I feel like a real wrencher. Figured I'd post this up since it's a GREAT way to make your own gasket.