I know this is an old thread, but I was getting my deuce ready for the local Veterans Day Parade and noticed the blinker wasn’t working. Upon investigation I found out I had another bad flasher unit. I remembered this thread from years ago and pulled it up.
My goal is to mount a EG22 flasher into the factory housing. I experimented with a couple of methods to remove the potting material. I first hit it with a 1/2 drill bit which worked but kind of stalled when I hit the circuit board. Then I tried a heat gun and screwdriver, which worked better. The heat gun will soften it up and I can break it up with the screwdriver while hot without too much effort.
My first thought was to take the flasher unit to work and use a mill to mill out all the potting, but not knowing the layout of the circuitry I didn’t want to hang a wire coming out of the plug and rip it out. I used the heat gun and screwdriver method to expose the end of the plug with the wires coming out. At this point I think I’ll take it to work tomorrow and mill most of it out now that I’ve got a rough idea of the wiring layout. After I do that I’ll use the heat gun and screwdriver to finish cleaning up around the plug terminals.
The heat gun method works pretty well. I would suspect you could clean it all out in about 30 minutes. I’m just taking it to the mill because I have one and it think it will speed up the process somewhat, but it is doable with just a heat gun and screwdriver.
My plan is to get everything out of the factory housing, wire in the EG22, and then make a aluminum cover to go on the back that will be held in place with the mounting screws.