A little repair ive been working on today

[Fazerruss]

This came in for repair. It's a left side engine case for a 1975 Honda CR125
At some point in its life the chain snapped and destroyed part of the case.
This is before


Starting to TIG up the hole


Machined a threaded boss and welded in


Milling out a new id plate


Welding that in


Lots more welding in pieces to restore the shape then back on the mill to whittle it down







Finished article

 

[frank horton]

v/nice....

 

[mtt.tr]

What repair.


That's super neat

 

[Pete.]

Very nice Russ.

Hotrodder did a similar job for me many years ago when the chain took out the clutch release arm housing on a Suzuki RM I think it was. I turned a stainless internal boss and he built up around it with weld.

Not nearly as much work as you've done here though

 

[Fazerruss]

Here is another repair I did. This is a gearbox off a 1927 James 350 that suffered catastrophic damage.

 

[Fazerruss]

 

[Fazerruss]

Very nice Russ.

Hotrodder did a similar job for me many years ago when the chain took out the clutch release arm housing on a Suzuki RM I think it was. I turned a stainless internal boss and he built up around it with weld.

Not nearly as much work as you've done here though

I've used similar methods myself

 

[Haz87]

Great job

 

[Parm]

Genius

 

[jgr2015]

Too modest by half on the thread title. There's more than a little bit of magic involved here.

 

[Fazerruss]

Genius

I wouldn't go that far. I just stick bits of metal back together that exploded!

 

[Fazerruss]

A couple more from the archive....
This case wasn't quite as bad. Also a bit of tin bashing. This mudguard was then going for re chrome

 

[Muddleengineer]

Now I feel totally incompetent

 

[finyuk2005]

bloody nice work!!
Whats your method of cleaning the castings before you weld? you seen to get them really nice and clean, do you still get crap boiling out when you weld?

 

[Migmac]

Here is another repair I did. This is a gearbox off a 1927 James 350 that suffered catastrophic damage.

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The first bike I rode was a James. Friend was given it, he was a ministers son so had a huge garden we could ride in. It was always breaking down, we probably spent more time watching it getting fixed than riding it. I was pillion the first few times and it seemed really fast, probably not even 30mph. We were still at primary school when the pal had it.

 

[Fazerruss]

bloody nice work!!
Whats your method of cleaning the castings before you weld? you seen to get them really nice and clean, do you still get crap boiling out when you weld?

These cases were clean to start with. The owner had them vapour blasted but you still get impurities coming out during welding. A lot of it is just the composition of the aluminium. Some cases are absolutely covered in oil and crap but they weld really nice. Usually the older stuff is nicer to weld than 70s Japanese.

 

[DickyDoDah]

You have some serious skills there