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There's a new filler gaining steam that has a higher strength than ER4043 that has Magnesium like ER5356 but at the levels to prevent hot cracking. In the July Edition of the AWS Welding Journal they specifically mention motorcycle framesand 356 casting repair. I like the idea because I'm a big prop...

That's fappable looking hardware you have there. I really dig how you mounted the black box in the little alloy box. I have a problem on an 01 YZ250 motor in an 05 alloy frame and the black box is huge compared to the 05 on up. Have it on the steering head right now but don't get max turning. Going ...

I didn't try as hard on the bottom.
Craigus

Here's mine for an 04 CRF250/500. It took a few months and a lot of mods to complete. Holds a little over 1.8 gallons. I used .060,.090,.125 and even a small piece of .25 for the seat post and rubber strap mount. Had the bung machined at work by a friend and welded it inside to reduce distortion. Mo...

IMHO the welded mounts are the way to go as long as the welding is done by someone who is skilled on aluminum and has a good machine. Those broken frames were most likely the result of stresses from a poor fitup and/or cold welds. Of course I'm a welder so I am biased.
Craigus

I think it's a factory weld. If you look closely you can see where there's some of the MIG weld showing and they just sweated over it with GTAW for cosmetic purposes. They use GMAW and GTAW on the frames with the wire feed in the places out of normal sight. They usually use GTAW on the wraps and the...

I tried drilling mine out to no avail. When I split the cases I took the bushings to work and had a machinist put them on a lathe. He said "they're harder than a preacher's dick at a double wedding". Better use a lot of coolant on a Bridgeport if you go the drill route.
craigus

I'd have to look at it closely as I just stuck it off to the side I was so bummed. I have all of the parts to fixit I just can't stomach it still since that fateful day when it broke.
Craigus

When I stuck a YZ250 smoker motor in my 04 CRF 250 chassis it was like that and wouldn't clear the spring and much worse than the 500 motor. I got a brand new Rad Valve and cut it adding a little more angle and it cleared it nicely. My 500 motor had an epic failure in the kick mechanism that resulte...

With the weld cracking down the middle like that I'd say they didn't have it prepped right where you could get a full penetration weld. With the Y section possibly considerably thicker than the down tube you may have a stress riser issue. Just because it's a pretty weld doesn't mean it's a good weld...

Mine did that on the second ride and it was completely fresh. I've since found another inner case and got the bearings and seals. Going to put it back together but not sure what I'm going to put the motor in. When it shattered it just bummed me the hell out so I put a spare modded 01 YZ250 motor in ...

It's become so politically correct where I work I have to call this a "fixture" no shit. I wish I'd had a jig when I did my conversion.
Craigus

When limited by the machine and circuit breaker you can do what was stated in mixing the helium, or you can switch to DCEN or Straight polarity which is what is used to weld steels, titanium and other hard alloys such as nickel bearing alloys. With DC on aluminum you use 100% helium and if you can a...

Denatured or iso it doesn't matter as it evaporates in seconds. In the aerospace field it's used almost 100% of the time when sawing aluminum and even some skimming operations.
Craigus

It's probably TIG but they fuse over the filler as opposed to dabbing it to make the row of dimes look. There's also an automatic wire feeder that can be hand held which I tried but didn't like or a wire fed TIG torch which I also thought sucked. Both of those builds look sweet IMHO. Craigus

Wish I knew what caused my case to bust out like that. I found a good right side case on eBay, so I'll have to get back on the 5 hunny.
Craigus

Alcohol works great for a lube during cutting and doesn't leave residue that will affect welding.
Craigus

To make my stock cable work with my ASV lever I heated the end up a bit to get the little metal goodie that covers the end of the cable sleeve to come loose and pulled it up and out of the way. I then got a vaer sharp pair of electrical snips and cut about ~ .300" off the length of the cable sl...

I'll start tearing into it shortly. Probably wear on the kick assembly caused it to shift or something. We'll see.
Craigus

I'll split the cases and check into possibly welding the damaged one or replace it. It's going to take a while and it sucks.
Craigus

I appreciate the encouragement and I didn't even think about April Fools Day, but having this happen kicked my ass. Haven't got a call so it may survive my blues for another try. It's just a sick feeling.
Craigus

My life turned to shit last Saturday. Went to start the Hoon and the kick mechanism fucked up resulting in busting the right case out taking the new late model primary case with it. It's a good thing there weren't any demonstrations going on in my neighborhood after that happened or I might have gon...

Took the 5 hunny on its maiden voyage. There were lots of loose bolts but it went great. She's a beast.
Craigus


http://www.youtube.com/watch?v=1NxhkiW_Z9k

http://www.youtube.com/watch?v=4ec-tA9EvgQ

Need to put a number plate on it and have to use 6mm threaded rod for the shift lever bolt as it won't go in from the bottom. Should take it up the road and into the woods for a spell. Craigus https://bannedcr500riders.com/images/auto/027d4f824883fae46f790f39f0cce4f8.jpg https://bannedcr500riders.co...

Looks great. I wish I'd have done the recessed threaded bungs for the shrouds, but got too far along and didn't want to get a lot of shavings in it. The whole project looks great and tell your welder thumbs up.
Craigus