any aluminum welders out there??? Check it!!

[aldochina]

was wondering what the best way to go about fixing this is. To me it would seem a real pain to try to weld the peices back in, I was just thinking maybe you could just fill in the bite by overlapping your beads. But I have no expierience so I may be wrong. I have someone who is gonna try fixing it for me. I am wondering why honda didnt keep this pocket solid, as It serves no purpose that i can see. Or atleast should have put a spine running back to brace it better.:wondering Poor design, considering how many are broken in that spot. I was shocked when i saw that there was no case saver under the gaurd!! considering every speck of the trike is all there and original. I checked my other one that I bought 2 yrs ago, and have never really rode cause its been awaiting a resto, thinking I could use that cover till this one gets fixed, and it was busted in the same spot!!
http://i674.photobucket.com/albums/vv103/aldochina/102_2471.jpg
http://i674.photobucket.com/albums/vv103/aldochina/102_2472.jpg
heres my exaust studs, that is the worst one. would like to replace them, stainless has been suggested for good reason. I am worried about removing them!
http://i674.photobucket.com/albums/vv103/aldochina/102_2470.jpg
heres the busted spacer, just ordered a few sets from a kind member. Hopefully they will be here soon along with the rest of my parts. I am dying to ride this thing.
http://i674.photobucket.com/albums/vv103/aldochina/102_2466.jpg
what do you guys use for removing gaskets easy!! took way to long to get the stator cover clean.
http://i674.photobucket.com/albums/vv103/aldochina/102_2467.jpg

[greythorn3]

http://img41.imageshack.us/img41/8885/102247231650863167987.jpg (http://img41.imageshack.us/i/102247231650863167987.jpg/)


for this i would drill them and pin them with the drill bit (break them off into the metal since it looks like a non pressure passage.. after putting jbweld on the joining surfaces.. looks like you could do it with 2 or 3 1/16" dril bits and it would be plenty strong.

[Name Brand]

A weld shop should be able to fix that without much very expense. They can also machine the pieces flat to the mating surface if they don't go back in true. They should check for trueness anyway.

To remove gaskets (especially on soft metals like aluminum) you should use a non-metallic scraper. Screwdrivers, putty knives and razor blades will easily gouge an aluminum case. I make my own in a few different widths like 1/4'', 1/2'' and 1'' wide. I cut a piece of plexiglass and file a 30 degree bevel on one side. The other cut sides can be sanded till smooth; I just put a few wraps of ducttape around it. You can also make points and hook shapes to get into tight spaces. I cut them all about 6'' long. With a file they are quick to resharpen.

JB weld is no good. If there are cracks in that cover JB weld will do nothing to stop them. Adding broken pieces of drill bit will likely condemn the part to never being able to be welded again since a dissimilar metal has been added. If the chain does hit it again the JB weld will never be as strong as a real weldment.

[lndy650]

jb weld works but its halfassed get someone to tig weld it. the drillbit idea would make it stronger ive used dowel pins like that.. oh and get a case saver!

[Erics350x]

That open cavity in the stator cover did exactly what its supposed to, break away without the cover shattering all over.

[oscarmayer]

^ exactly what I was thinking.

i am wondering if your chain is either too worn and needs replacing or too loose. it should not be hitting the case at all.

[lndy650]

the key to avoiding this is to have good sprockets and keep the chain tight.

[Thorpe]

Have someone with a tig welder build the void up with weld, and grind back to perfect... JB weld sucks, I wouldnt trust it....

[aldochina]

Have someone with a tig welder build the void up with weld, and grind back to perfect... JB weld sucks, I wouldnt trust it....

this is the approach I thought would be best!!

[Dirtcrasher]

Do you have to bother with it at all?? Doesn't the gasket cover the sealing area just behind it??

If no oil or contamination happen in that cavity, fill it with black silicone if your concerned about garbage getting in there.

Sure, get it tig welded if possible, but for some reason it seems nearly impossible to find good Tig welders for most of you guys. The weld is either junk or they get the metal so hot it warps the metal. I do believe that HRE can take care of you though......

If you run up to a 14 toothed front sprocket, you can run the case saver and it won't happen again.

Some may feel it's a poor design, but at least it doesn't destroy a clutch pivot boss such as a thrown chain on a 250R..... which always results in the "WTB, Left 250R case"

I've gotten those head bolts out before a few times :D I'm gonna start a thread on it :)

[aldochina]

yes, i could leave it, it wouldnt hurt anything, but the guy is gonna fix it for free, and he does weld for a living, so why not. It is the cousin of a freind of mine, and if he does nice work, which i would imagine he does, I thow him a few bucks, and then if i ever need him again, he'll help me out!! the same spot is broke on my other 350x, and it did have a case saver on it, somewhat bent though. I like to run most all my stuff as stock as possible.

[Dirtcrasher]

Oh, ok, thats cool :D I just see ALLOT of horrible TIG welds.... Hopefully he's good at it ......

You know me, I'm always Mr do it once, do it right!

If you take the head off, I can get the studs out in my mill........

[aldochina]

thanks for the offer Dc, I may take you up on it, but dont want to pull it that far apart just yet. I want to get some fun out of it first. The plan is to take it down to nothing and reasemble like new, but we all know how long that can sometimes take, so I'm getting it mechanically sound, gonna slap some riding fenders on and probably run it for the winter anyway!!