Al motorcycle case repair?

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I can't see any way to weld this other than machining out the cracks completely and then some more for torch access. Any other opinions?Left case 3 separate cracksRight case, cracked through the threads.Last edited by jar944; 04-10-2014 at 07:42 PM.
Reply:Is that the right side of an engine case?GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Right and left
Reply:I hate to tell you this but the tolerances are so tight that if you don't have all the right equipment you aren't going to have a balanced motor when you are done. On top of that i doubt any fix for this would last very long. IMO you are much better off buying new cases or a salvage motor with not many miles on it.God luck man.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Originally Posted by GravelI hate to tell you this but the tolerances are so tight that if you don't have all the right equipment you aren't going to have a balanced motor when you are done. On top of that i doubt any fix for this would last very long. IMO you are much better off buying new cases or a salvage motor with not many miles on it.God luck man.
Reply:Originally Posted by GravelI hate to tell you this but the tolerances are so tight that if you don't have all the right equipment you aren't going to have a balanced motor when you are done. On top of that i doubt any fix for this would last very long. IMO you are much better off buying new cases or a salvage motor with not many miles on it.God luck man.
Reply:Originally Posted by jar944I can't see any way to weld this other than machining out the cracks completely and then some more for torch access. Any other opinions?Left case 3 separate cracksRight case, cracked through the threads.
Reply:Ive seen worse repaired. Use a straight die grinder, cutting bits, and go to town.What year cr500? Or do you just have the engine?
Reply:Originally Posted by GambleWhat would balancing a motor have to do with this? If it's just the outer covers, the only thing to be rotated in the rotating assembly...right? Or am I missing it completely?
Reply:Repaired lots of those similar deals. Die grind with small burr into the crack and tig fill with 4043  or 4943 if you  can get it.Draw file the flats back and your done. On the cracked threaded holes install a time sert and call it good its not a Swiss watch you will be fine, as long as you seal any possible air leaks it's a no brainier.... Last edited by B_C; 04-11-2014 at 12:17 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:I'd go for it.  After putting heat into it, cover it with a welding blanket, give it some time to cool, then do your machine work.  Can't wait to see repair pics.  Trade my 1990 CR500 for the Hardinge Lathe in my sig.-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:Originally Posted by turismolover22Ive seen worse repaired. Use a straight die grinder, cutting bits, and go to town.What year cr500? Or do you just have the engine?
Reply:That is a rather easy fix. I did one on a CR250 that blew a quarter sized hole thru the bottom of the case. I filed the case weld flat, then taped a piece of 600 grit wet dry to a granite layout stone and did a figure 8 till I had a even pattern then I knew it was flat.... Saved my buddy $350.00 bill. the local dealer didn't even notice the repair till he had the engine back together.TOOLS AND TOYSSMAW Mid States Inc. "MISSING LINK" 10-150 AMP Buzzer circa 1945ishSMAW Magic Wand 40-60 AMP Suitcase Buzzer circa 1939ishGMAW Hobart 210 IronmanOxy-Propane TorchMany other old and cold goodies"Rusty but Trusty"