Considering what I was about to do, I figured a scatter shield was in order.  A chunk of wood ought to be safe.

First up, a stock cam.  I did a 5X visual and it looked perfect.  There were no visible defects.  A nice coat of moly-lube will ensure that the torque is applied smooth and consistent.

First stop, 200 inch-lbs.  I cycled it a few times to 200 inch-lbs.  The reference dimension dropped to 54-7/8”.  Probably bedding in.  So far so good.

Next stop, 250 inch-lbs.  I cycled it a few times to 250 inch-lbs.  The reference dimension remained at 54-7/8”.  That’s good, no yielding.

Next stop, 300 inch-lbs.  On the second cycle, “POP”.

Next up, Sneezy’s AR500 release cam.  I had to dress it up a bit with jeweler’s files to get it to slip onto the test shaft.  It was quite a bit looser by the time I was done.  Oh well, hope that didn’t screw things up.

After a few cycles at 150 inch-lbs, it was time to put it to the test.  The reference measurement was 53-5/16”.  I attribute the drop to the loose fit and a slightly deeper ball socket for the pushrod.

First stop, 200 inch-lbs.  I pulled it five times to 200 inch-lbs.  The reference dimension remained at 53-5/16”.

Next stop, 250 inch-lbs.  Same drill, five pulls to 250.  The reference dimension remained at 53-5/16”.  Lookin good.

Next stop, 300 inch-lbs.  Five pulls later it had not snapped.  I think that’s a good sign.  The reference dimension dropped 1/16”.  It was now 53-1/4.  Was it yielding or bedding in?

Next stop, 350 inch-lbs.  Another five yanks on the T-wrench.  Things were lookin good.  The reference dimension dropped another 1/16” to 53-3/16”.  Hmmmm?  Somethin might be yielding.  Time will tell.

Time for some serious twistin.  Have to admit I was getting a bit nervous.  I was pullin on that long handle pretty hard.  But what the heck, the stocker snapped and it didn’t kill me.  No guts no glory.  

Onward to 400 inch-lbs.  Let’s get serious, go for ten pulls.  So, ten pulls to 400 inch-lbs and it was still in one piece.  The reference had dropped to 53-1/16”.

I was getting froggy.  Didn’t hesitate to amp things up to 450 inch-lbs.  Ten pulls later the reference dimension was still at 53-1/16”.  I’m likin that.

The torque wrench only goes to 600 inch-lbs.  I didn’t want to have the thing snap when I had the needle buried, so I decided I would go to 500 inch-lbs and call it a day.  Ten pulls later the release cam was still in one piece.  Wow!  That's 42 foot-lbs.  

The reference dropped to 52-7/8”, so we were lookin at a change of 7/16”.  Over a span of 21” (the wrench is 21” long) that’s pretty much nothin (2%).  

The post-test visual inspection will tell the story.

Here’s a shot of the other side.  It took 42 ft-lbs of torque and didn’t even flinch.  That’s no guarantee that it won’t develop fatigue cracks over time, but I think that is highly unlikely given the expected load.

You install the shim between the push piece and the release bearing.  The shims come in .010” and .020” thickness, so you can fine tune the pushrod in quarter-millimeter increments.  With these shims, it’s easy to dial the lever position right down to the gnats-a$$.

Great test methods as usual......Thanks for doing this.

I had a clutch case and some stock and Sneezy cams sitting in the corner of my shop collecting dust waiting for a day when I could get some form of test devised.  My test method would not have been nearly as precise and measurable as the one you devised!

It appears the laser cut release cams could handle some big increases in spring pressure - but then the weak point will likely become the outer plate that holds the bearing and pushes on the spring......especially the ones that have been machined to allow more clearance for the extra plate in the DR650 clutch modification you devised.

But you have so far proven that bigger/badder/stronger springs may not be needed....and that the release cam that Sneezy had built is far superior to the stock one made from metal pasta.    

DBM - thanks for setting up this test.  Unfortunately I do not have the equipment in my shop to set that up (1-2-3 blocks, overcenter clamps, etc.).  After my initial investment in manufacturing these, I was not willing to start buying more tools and equipment (I know, you can never have too many tools!) at this point.  I really appreciate the time you have taken, and the compliments.

Note - I have about nine left if anyone else is still interested...