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Author Topic: welding engine case damages  (Read 670 times)
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silly
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« on: September 16, 2017, 03:47:07 PM »

any thoughts on welding up holes in cases? tig weld available. any tips? hole in chain area. what all issues are involved?
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scottysg
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« Reply #1 on: September 16, 2017, 08:35:30 PM »

I had to weld up a crack in the clutch cover on mine after a tumble, and also a hole in the rear of the engine after drilling the swingarm bolt hole and narrowing that part of the motor to fit in my 250 frame. after 30 years of oil sitting in there, that aluminum really soaked it up. I spent a long time cleaning and wire brushing and I was still burning oil. if you are a good welder it may be no issue. all I can say is clean the hell out of it and burn the oil out of the area with your arc then re clean and repeat before you really get a puddle going. aluminum is a pain as it is so make sure its clean. good luck its doable just tedious.
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Heniz
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« Reply #2 on: September 20, 2017, 03:31:19 PM »

Strip engine cases completely. clean clean clean as much as possible and prep the surface. Ive used a contact cleaner or something that evapourates fast to prep the weld area and as allways with alloy pre heat the alloy with a torch so its not to hot but not to cold. basicly you want to drop a couple drops of water onto it so it just sizzles. Good luck with the repair and its all about prep work. Make sure you get somebody who tig welds aluminium every day to do the repair as some castings can be very hard to weld.
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silly
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« Reply #3 on: October 10, 2017, 07:14:44 AM »

 crown alloys suggested filler rod royal 100 fco  or  royal kirkrod.
 to repair high sinc engine case aluminum material.
 brazing best choice, or tig weld.

 I will post my results.
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RoostiusMaximus
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« Reply #4 on: October 13, 2017, 08:38:46 AM »

bake the oil out on a hot plate before attempting to weld it.
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silly
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« Reply #5 on: October 13, 2017, 07:17:25 PM »

worked out better than I expected, but its still tricky to do. I used a inverter 200 tig welder ac balance 60 and frequency 170 at 150 amps . I used the crown kirkrod 1/8 or smaller size rods. you need stainless wire brushes and acetone to clean.
 I bought a 1/2 pure copper tube from plumbing store and that fit inside the clutch arm, so it backed up the hole I needed to fill with weld.
 I made a new weld bung out of solid alum. round bar material, then drill and tap for new drain plug, I bought a 10mmx1.5mm 2007 kx250 drain bolt.
 I plan on welding a sheet skid plate to chassis to protect this engine.
 
 the tig welder is great for being able to flow out or fill all porous pin holes that can delevope.
 the repair turned out great in my opinion. but that filler rod is tricky.
I couldn't figure out pics to add
  I
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umberto
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« Reply #6 on: October 13, 2017, 07:31:49 PM »

worked out better than I expected, but its still tricky to do. I used a inverter 200 tig welder ac balance 60 and frequency 170 at 150 amps . I used the crown kirkrod 1/8 or smaller size rods. you need stainless wire brushes and acetone to clean.
 I bought a 1/2 pure copper tube from plumbing store and that fit inside the clutch arm, so it backed up the hole I needed to fill with weld.
 I made a new weld bung out of solid alum. round bar material, then drill and tap for new drain plug, I bought a 10mmx1.5mm 2007 kx250 drain bolt.
 I plan on welding a sheet skid plate to chassis to protect this engine.
 
 the tig welder is great for being able to flow out or fill all porous pin holes that can delevope.
 the repair turned out great in my opinion. but that filler rod is tricky.
I couldn't figure out pics to add
  I
I just finished a guide to posting pictures using Imgur. It's pretty easy to use.

http://www.kxriders.com/forums/index.php/topic,16965.0.html
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silly
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« Reply #7 on: October 13, 2017, 08:20:32 PM »

 pictures. my computer gets a failed recovery when the im not a robot is required. happens on other sights also. I didn't get either way to work still.i tried both instructions on pics.
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silly
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« Reply #8 on: October 14, 2017, 12:33:02 PM »

worked out better than I expected, but its still tricky to do. I used a inverter 200 tig welder ac balance 60 and frequency 170 at 150 amps . I used the crown kirkrod 1/8 or smaller size rods. you need stainless wire brushes and acetone to clean.
 I bought a 1/2 pure copper tube from plumbing store and that fit inside the clutch arm, so it backed up the hole I needed to fill with weld.
 I made a new weld bung out of solid alum. round bar material, then drill and tap for new drain plug, I bought a 10mmx1.5mm 2007 kx250 drain bolt.
 I plan on welding a sheet skid plate to chassis to protect this engine.
 
 the tig welder is great for being able to flow out or fill all porous pin holes that can delevope.
 the repair turned out great in my opinion. but that filler rod is tricky.
I couldn't figure out pics to add
  I
  also aluminum will pull and shrink bad. so I left old bearings in and had the cases bolted together. in case any warp, happens this might help. but I did not notice any shrinking of aluminum on this project. but don't gamble.
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