72 Triumph engine welding

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Got two parts done, need help on the third 72 Triumph 650 5 speed with cracked motor parts.I consulted with weldermike to make sure the aluminum is weldable - thanks Mike This customer is my cousin - so he pays double right? Stupid epoxy of some kind plugging the hole.It was plugged already so I cut it off.Blended downProbably take two more posts to get the rest up.Last edited by MinnesotaDave; 10-25-2014 at 07:13 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:All blended and contoured.I flat filed the gasket surface by hand.Busted port on side cover.Ground a bolt to fit through the oil passage - it needs to stay open.Contoured smooth.Next...Last edited by MinnesotaDave; 10-25-2014 at 07:14 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Sanded out and ready.Here is where I need help I already consulted with weldermike and I'm still not sure how to get into this spot.The crack is almost 1" deep and goes all the way down.I can't figure out where to put my torch and filler??? Last edited by MinnesotaDave; 10-25-2014 at 07:16 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Could you remove the small piece next to the crack and build it up? Can't see much from my phone.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Dave if that's a tappet/valve cover and doesn't have pressure on it I'd say weld what you can. Option 2 is machine the bolt whole completely out, leaving a good wall for the valve chamber. Machine another "bolt hole" you could thread in or to where it is more friendly to weld. Hell I don't know.Arcon Workhorse 300MSPowcon 400SMTPowcon SM400 x 2Powcon SM3001968 SA200 Redface1978 SA250 DieselMiller Super 32P FeederPre 1927 American 14" High Duty LatheK&T Milwaukee 2H Horizontal MillBryan
Reply:Originally Posted by blawlessDave if that's a tappet/valve cover and doesn't have pressure on it I'd say weld what you can. Option 2 is machine the bolt whole completely out, leaving a good wall for the valve chamber. Machine another "bolt hole" you could thread in or to where it is more friendly to weld. Hell I don't know.
Reply:Originally Posted by 7A749Wouldn't hurt that engine one bit to take a little of the cooling fin out to get the tungsten in there. Gas lens with as much stick out as you can get, go to town. Now, I'm not a motorcycle repair guy, but I've repaired my share of feeder drive castings and I always machine out broken sections like that, reweld and build up, then remachine it. Of course, if you do not have a mill, then it's a little trickier but not impossible by a long shot.You could also opt to put a large groove in the center where the crack is, weld it up, re drill and tap the hole.As was said, you can prolly just surface weld it up, finish the gasket edge and call it good.
Reply:In case anyone wonders, the big case half (first set of pics) welded really easily.The small cover (second set of pics) was a junky piece of metal - weld, grind, weld, grind, to get out the crap.I think it took me four or five weld/grind cycles to get it to clean up.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:I know a guy that specializes in stuff like that including welding up new cooling fins. He said some of the British bikes have the dirtiest castings. I haven't done very much aluminum but what impressed me was how he tacked a new aluminum TIG rod onto the short stub of the old one he left stuck in the puddle. Pretty good control on the foot pedal and a steady hand holding the rod. No rod stubs all over the place.
Reply:Looks like a fun job Dave. If I was doing it I would just take the broken piece out, clean the threads out and rebuild the aluminum and drill and tap it. I've never had much luck welding those little pieces back on. The reason is that it's not likely you will get the threads matched perfect and if not when you screw the bolt in the pressure expands and breaks out the piece again. At least that's my experience anyway. Plus if you take the piece out it looks like you will have enough room for your torch to get in to build it up without removing any fins to retain the original look better.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:JB that sucker!GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Originally Posted by GravelJB that sucker!
Reply:MinnesotaDave,I have a triumph around same year where I have the same exact break in your first picture I am working on.  When I took the cover off there is a rod and linkage connecting to that hole.  I'm curios what is that's for ?If I can just plug weld it like you it would make my life easyMiller 350PMiller 30AHobart trekHTP Invertig 221
Reply:Originally Posted by padronanniversaryMinnesotaDave,I have a triumph around same year where I have the same exact break in your first picture I am working on.  When I took the cover off there is a rod and linkage connecting to that hole.  I'm curios what is that's for ?If I can just plug weld it like you it would make my life easy
Reply:Finished the head - I cut the broken piece shorter and then built it up from there.He told me I didn't need to blend it down, he was going to have the machinist do that part.Then he would drill and tap it.They also brought a another motor case to fix cracks in, and an old Triumph frame with three cracks and a bend to straighten.At least they brought donuts Burned up two wp-26 torches between the four aluminum parts  (threads seized in the head)So I'm finally ordering a wp-20 torch and cables this week. Only need a couple parts to connect my carbonator pump and old beer keg - should end this problem...Thanks for the advice guys Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Great save Dave sorry I missed this. Ive been doing field repairs lately and been missing a lot. Iv'e hardly been on and when I am it seems people just wanna argue with me lol, F em! Great job! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Looks like it turned out great Dave, a little mill work and never know a repair was made!
Reply:Originally Posted by weldermikeGreat save Dave sorry I missed this. Ive been doing field repairs lately and been missing a lot. Iv'e hardly been on and when I am it seems people just wanna argue with me lol, F em! Great job!
Reply:Not to completely derail this thread, but this guy has a ton of Triumph/BSA and some norton stuff. I have a couple of Triumphs, a Harley or 3 and an ancient Velocet. Hutch knows his **** too. Don Hutcinson Cycle Center, Wakefield, MA. http://hutchinsoncycle.com Its better to call, doesn't have a lot of stuff listed on the site.Miller Big 40GMiller HF-251 D High FreqVictor OA Lincoln 135 MigMK 3A CobramaticBridgeport J HeadCronatron OxylanceRadnor ACAG TorchWeldcraft TIG Torches1 blown knee and two 5 Gallon pails away from being a hero.
Reply:Nice work there Dave! I have a triumph in the shop that's awaiting a resto with a cracked frame. Suppose it's not un common, those frames are about as big as a Popsicle stick!Real welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:Although your already done, I often use a piece of carbon arc rod to stick in a hole and weld right up against it. Saves almost all the hole that way. The carbon rod is very easy to drill out after welding too.ChrisAuction Addict
Reply:Originally Posted by Cape Cod GaryNot to completely derail this thread, but this guy has a ton of Triumph/BSA and some norton stuff. I have a couple of Triumphs, a Harley or 3 and an ancient Velocet. Hutch knows his **** too. Don Hutcinson Cycle Center, Wakefield, MA. http://hutchinsoncycle.com Its better to call, doesn't have a lot of stuff listed on the site.