Suzuki 650 V case tabs

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Dave,    We put the motorcycle back together and the motor is working great.  Thanks for the quick repair work!    John *****        **************************************Above is nice note from the customer. Below is not-nice, busted cylinder jug tabs from bike on pavement. Tabs are part of the case.Repair criteria did not include making things look 'pretty' or 'new'. Just functional.Repair consists of:-tape and seal all openings in the engine—which customers characteristically, leave open-piston was already removed by customer, who supplied new sleeve-on critical weld up, re-drill, re-tap repairs; I always order new, industrial grade, first classM-42 cobalt tap drill and titanium nitride coated tap (gold colored taps, which really cut easily,with noticeably less drag, in aluminum with special tap lube)-make pasteboard template of the minimum pattern for the welded up areas, from the new jug, to confirm that the tabs are big enough, etc.-Grind out enough of the tab bosses to expose the thread area. Carbide burr the threads-out, then begin weld build-up.-TIG areas with high strength, ultra-quality, Rockmount or Eutectic aluminum rod.     TD 300 GTSW, #20 flex-loc torch, gas lens. An inverter like this, produces significantly less TOTAL heat input to the work, being able to focus the arc very tightly; which isn't the case with big transformer machines.  -Grind out enough of the tab bosses to expose the thread area. Carbide burr the threads-out, thenbegin weld build-up.-TIG areas with high strength, ultra-quality, Rockmount or Eutectic aluminum rod.     TD 300 GTSW, #20 flex-loc torch, gas lens.  -Welding required about 10 passes/per tab, with fast cool down via water, to negate distortion, expansion contraction problems. Max interpass temperature runs 200˚F, or less.[Some 'professionals' may slam my doing this.However—for whatever this is worth—I've have outstanding results, reliability, no distortion, cracking, problems in this 'abusively fast cool down' method; for some 16 years. Including100's of motorcycle cases, aluminum and cast iron blocks, transmissions, bell housings, etc.........and some rather pricey Pratt & Whitney Turbojet, Helo engine, 410SS, hot section cases ($1,000,000—used)     --I've got some rather practical, technically valid reasons for doing the fast-cool. The 'professionals' don't.]****There are cases, where attempting to weld a casting, which is under significant stress, or tension (bolted into another assembly, with weight bearing thru the assemblies), that just will not work. Some styles of castings, that I term 'captive', are not conducive to any form of welding, they'll show cracking right behind the liquid weld bead. But, 99% of the others, can be successfully welded.********[That being said, I'm just a farm boy—so whatever I think, say, or do, can't amount to squat.]-Grind, then sand tab tops close to flush, then draw file tops to flush.-get 2 new, Suzuki cylinder bolt alignment dowel-sleeves from customer. Have to use these sliding fit sleeves to establish alignment of the jug. -use transfer punch to locate the pilot drill for the new tapped holes for the jug mounting tabs, which are threaded studs, with nuts--lift the jug back off---and BINGO! one of the sleeves, hangs up in the jug momentarily........then drops......down into the case.[OHHHH-sh*t—OH—DEAR!.........luckily find and retrieve errant sleeve with magnet. Sternly warn customer—not to do, what I did.]Setup a perpendicular drilling, hand drill-that's in a fixture, pilot drill then tap drill, then tap.Blackbird
Reply:After reading your posts, I almost went out and used a sledge on my transformer-based Syncrowave 200...I said almost. Looks like a nice job. I'll have to struggle along with what I've got......
Reply:Originally Posted by gnm109After reading your posts, I almost went out and used a sledge on my transformer-based Syncrowave 200...I said almost. Looks like a nice job. I'll have to struggle along with what I've got......