ATV Frame Failure . . . need advice on repair

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This is from a 1998 Honda Foreman.  The frame finally failed at the swingarm attachment, starboard side. It looks fixable and will be a good project, but I don't really know what steel type or thickness I should use for the repair.If you have any advice, please let me know.  In some of the pics, you can see the prior frame repair that was done by a local welder.  The frame was originally damaged due to being used in a saltwater marsh.  Last edited by bluduk15; 11-11-2007 at 10:31 PM.
Reply:Wow! That's gonna all have to come apart to repair it properly. Take it apart and post more pics.Maybe it's time to trade it in on a new Bombardier CanAm!
Reply:Mild steel and a MIG is all you need.You sure do have to take it all apart first.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I would build a whole new frame from scratch, and slap all the honda guts into it.Miller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:I have done almost that same exact repair, but the one I worked on was broken on the lower frame tube just under the swing arm mount.  It looks like the entire bearing/mount surface is rusted out on yours.  OEM Honda frame tube is =/- 16g (pretty thin) and that plate mounting surface is close to 14g.  I used .065 dom tube and .125 plate for my repairs.  I don't think I took any pics, but I am not sure they would help.  Just take your time and duplicate the opposite side.
Reply:I am already breaking it down.  There is more room than it appears in the pictures.  There really is only one place that would be difficult to get the mig gun into because of the crankcase.Airwolf: Did you have to take the engine out to do your repair? Thanks
Reply:Originally Posted by bluduk15lready breaking it down.  There is more room than it appears in the pictures.  There really is only one place that would be difficult to get the mig gun into because of the crankcase.Airwolf: Did you have to take the engine out to do your repair? Thanks
Reply:imagine what the H-shop would charge if you took that in? A complete new frame just for starters. You may get by with less than a full strip, but as has been said, be careful of the engine and lubricated parts and seals. Also if you arc the engine case you could possibly do internal damage to shafts or bearings. Moving parts and electric arcs don't play well together. There is also that fact that molten steel is far above the melting point of aluminum. At least cover well.SA200,Ranger8,Trailblazer251NT,MM250,Dayton225AC,T  D-XL75,SpoolMate3545SGA100C,HF-15-1  RFCS-14 When I stick it, it stays stuck!
Reply:Here is a closeup of the repair area. It is a sheet of relatively thin gauge metal that is folded over like a taco.I am thinking of replacing it with 1/2 in. plate or two 1/4 in. sandwiched together.  How do I cut the hole for the stud mounting collar? I have an oxy/fuel torch, but that doesn't seem precise enough.Are there hole saws that will do it? Last edited by bluduk15; 11-13-2007 at 12:59 AM.
Reply:1/8" would be plenty if its 1/16 originally.  I try to always put back more than was there, but 1/2" is over kill even for me. David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David R1/8" would be plenty if its 1/16 originally.  I try to always put back more than was there, but 1/2" is over kill even for me. David
Reply:I get the best results for a hole that size from a bi-metal hole saw in a drill press.  I have seen guys who can do it with an O/A cutting torch or plasma cutter but I never got in enough practice with either of those.
Reply:I would use a hole saw because you can locate the center with a center punch.Its a hell of a lot easier to cut a hole in 1/8" than 1/2".  Its your machine. DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Okay, things are actually moving along. I got the new strap welded in the elbow of the frame and then a new plate fitted.The collar that will hold the stud is also ready.  Here are a few new pics. Hole prepared, notice frame wasted awayNew strap in, lots of extra metal, I knowNew plate fit up. 1/2 in. overkill...I'm still looking for suggestions on how to index the other hole and make a good mark to get a nice fit up for the swingarm.
Reply:Okay, she's back in business.  With some great help, "IT IS ALIVE..."All welded up (compare to pic in #9)Painted with swingarm attached. Notice new stud bolt in collar.  That collar has a lock nut shaped like a castle nut, which needed a special tool...Here is the tool Joe made out of a big socket.  The Honda tool is $85.00, Joe's was $1.19. Thanks for everyone's help.  Yes, I disconnected all of the electrical before I started welding.Last edited by bluduk15; 11-21-2007 at 02:33 AM.
Reply:ha ha ha!!tell Joe he´s a master!I can´t believe you used 1/2 in plate. It won´t flex, trust me  good work!My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Nice Job!Time for some ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Cool fix. Looks great and solid.Now follow Zaps advice above Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.