Need expert advice (aluminum)

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Hello everyone. I am new here to the forum and have an issue needing guidance from the PROS. Here it goes... I was nailed by a drunk driver on my motorcycle (specifically a 2005 Suzuki Hayabusa with a "Rigid twin-spar aluminum frame") and now the bike is getting ready to be taken apart and customized from top to bottom. I have contacted many different shops throughout the US for doing a repair on the frame and everyone has different methods from TIG welding to HTC 2000 rods. Everyone I spoke to just seemed like they were wingin it just trying to get me to send in the frame and get the cash. I need real expert advice from you guys. The frame is perfectly straight but has about a 3 inch gash of metal taken out by the asphalt. Almost like a severe road rash about a centimeter or so deep. *WHAT I NEED TO ACCOMPLISH* Frame is going to be sent in for some powder coating or chroming ( I haven't decided yet) and need the best weld to fill in the gap that will hold like the aluminum its made of. Sanded and polished and coated like it was NEVER there. I need the weld to NOT prevent chrome or powder coating from sticking and holding to that section which was repaired. This bike is getting about $15,000 in parts and paint and will be made more for show. ALMOST ON MY KNEES BEGGING FOR HELP AND NEED THE ABSOLUTE BEST COARSE OF ACTION TO TACKLE THIS PROBLEM!! New frames are about $3,000 so I dont want to go that route. Picture enclosed to help give a better idea of what it looks like. Notice that the aluminum seems to be abit more coarse rather than smooth like other spots.  Thank you all very much for your time. Attached Images
Reply:Originally Posted by Ac1dTr1p:  Picture enclosed to help give a better idea of what it looks like. Notice that the aluminum seems to be abit more coarse rather than smooth like other spots.
Reply:Im in Phoenix. Where are you located?  What are you thinking as far as how to tackle it?
Reply:Originally Posted by Ac1dTr1pIm in Phoenix. Where are you located?  What are you thinking as far as how to tackle it?
Reply:Do you have a shop? I would prefer not to send it to a random person if all possible. How much?
Reply:Originally Posted by Ac1dTr1pDo you have a shop? I would prefer not to send it to a random person if all possible. How much?
Reply:Just FYIZap does work for me via the internet...He isnt some random guy...I would classify him and the Chuck Norris of welding...
Reply:No need to send it across the country, reason you got a bunch of different answers is because there is probably more than one way to do it.  Since the picture is absolutely terrible its hard to determine exactly what needs to be done.  The part does seem to be cast but if it isnt then its probably heat treated and welding it will create a weak area in the frame which on a sport bike is a big no-no.Your in AZ, there is motorsport fab shops all around you, Im sure if you ask around you can find someone to vouch for at least one of those shops.  Assuming it is cast, this looks to be a very simple repair that any shop with a reputation can handle.Have we all gone mad?
Reply:I dont know if that is cast, or just the texture of powder coat.UA Local 598
Reply:Originally Posted by WHughesI dont know if that is cast, or just the texture of powder coat.
Reply:Thanks for some of the feedback guys. Im gonna go ahead and take some really nice pics when I get home today so you guys can get a better idea of whats really going on. Please check back tonight.
Reply:Aluminum motorcycle frame, high-powered motorcycle ('Busa), high-speed motorcycle ('Busa) all just SCREAMS that this needs to be DoneRight.Not guess.  Not 'almost'.  DoneRight.Because aluminum is not all that forgiving as a structural item and/or as a welded structural item.Step One:  Find out for absolutely sure what alloy(s) the aluminum Hayabusa frame is made of.Step Two:  Find out for absolutely sure if the aluminum alloy(s) used for the Hayabusa frame is/are even weldable (not all aluminum alloys are weldable).Step Three:  Find out for absolutely sure that even if the aluminum alloy(s) used for the Hayabusa frame is/are weldable, that there aren't special post-weld heat treatment procedures that may be needed.The Official Suziki Hayabusa webpage at Suzuki mentions the current frame as being made of a combination of cast and extruded aluminum sections with a steel rear subframe (web scuttlebutt mentions possible cracking problems in the '99 and '00 models and thence the change to the steel rear subframe in subsequent models).And YES, a 1 cm deep gouge in a light-weight aluminum structural member on a high-powered, high-speed motorcycle -IS- a BigDeal.Pictures don't tell what the alloy and specs are.  You really have to find that out first.It may turn out that the answer is to GTAW the gouge with a certain filler.It may turn out that the answer is that the frame is now scrap.  The best laid schemes ... Gang oft agley ...
Reply:I don't know a whole lot about welding but I do know a bit about sportbikes.  If it was a Ninja 250 it would be different, but there is no way I would ride a Hayabusa that has had the frame welded.  Everything on a bike is about 10x more serious than on a car or truck.  You only have 2 tires and only a tiny fraction of those tires is actually on the ground.  I guess if it is strictly a show bike though it may not be a huge deal.  I'd just feel uncomfortable if I sold it years later to someone who planned on riding it all the time.Did you take the frame to Computrak or someone to laser it?
Reply:new frame is $3k?  why not do a fully custom with a new frame?  you're gonna be putting a boat load of money into this bike, why start with a damaged frame?  Maybe after its all welded, it'll be good as new, but I'm not taking that chance (especially with a 'Busa... but if you plan on crusing it at under 35mph, then i'll just shut up).just get an used Busa and build from there.it would kinda suck if after you get all the fancy, shiny, polished, anodized parts on the bike, and then have a frame failure and scratch everything up and have to start over again... i'd rather spend the 3k.but then again, I ride an SV650 and tour on a VFR800, so i might not know what i'm talking about.
Reply:I have a '98 gsxr 750.  Aluminum frame, some is cast and some is not, and it IS WELDED in a bunch of spots.  I would almost guarantee that your bike is weldable - but who does it is important.  Lots of unknowns so far - but I wouldn't say it's impossible by any stretch.  If it were me, I would take it in to a couple shops that look reputable (or have good feedback for aluminum work) and ask them how they'd do it, then go do your research to see if that seems good - or come back on here and Zap can tell you what he thinks, since he's the master (or so I read).One other thing - some bikes have hollow frames, so a gash might take it down pretty thin.  Again - it's all just speculation at this point.As stated above - you could get a POS bike for less than $3000 I think and start with a fresh frame and have all of the extra parts and a whole differnet engine (I'm thinking........ GO CART with a busa engine!!)Millermatic 135Syncrowave 250