Welding magnesium alloy crankcase

[Richard.]

Possibly but unsure how I’ll get it to seal. I trust your judgement. I’ve got your pm and I’ll give you a message once it’s on the way. Cheers

When you or I drill it out your going to reduce wall thickness. I don’t see how that has any effect on sealing by reinstating that wall thickness again where it cracked. See photo. Build up the red box to compensate for the extra meat you take out the hole. Do you see any potential issues doing that?

 

[Toleman]

What I meant was if the crack was just welded I’m not sure the original bolt would seal.

I don’t see why not as it doesn’t have to look anything. An improvement on the original design for durability is a win win in my books.

I’m unsure why they all crack there. It’s a motorcross bike not an enduro so I can’t see it getting hit by things. Unless it comes down to over torquing. It will of been in and out a lot as the oil change interval is 5 hourly on these things.

Appreciate all the responses

 

[roofman]

What I meant was if the crack was just welded I’m not sure the original bolt would seal.

I don’t see why not as it doesn’t have to look anything. An improvement on the original design for durability is a win win in my books.

I’m unsure why they all crack there. It’s a motorcross bike not an enduro so I can’t see it getting hit by things. Unless it comes down to over torquing. It will of been in and out a lot as the oil change interval is 5 hourly on these things.

Appreciate all the responses

ive got a kit here that contains a tap and a size bigger sump bolt...ime willing to send it down for free if you want it but i need the tap sending back to me when your done

 

[Richard.]

Ok. Toleman Send it up. I’ll have a looksy

 

[roofman]

Ok. Toleman Send it up. I’ll have a looksy

Richard as above post...if you need the kit then let me know,all for the cause so to speak

 

[Richard.]

Richard as above post...if you need the kit then let me know,all for the cause so to speak

It’s very kind mate. See what toleman says. If he wants to use it by all means send it and bill him. If so I’ll make sure you get your tap back.

 

[Toleman]

Roofman that’s very kind of you. Make sure you include a paypal address, I’d atleast like to cover your postage and a beer.

I can then send it back when I collect from Richard.

I’ll be on the hunt today for a box and some packaging.

 

[Toleman]

Those bearing retaining screws are apsolutely solid. Wish they had used hex heads.

Will heating them up help do you think?

 

[Jlg]

Those bearing retaining screws are apsolutely solid. Wish they had used hex heads.

Will heating them up help do you think?

Id say heating around the screw would do the trick

 

[wyn]

I used to use one of these hand impact drivers on mx bike cases.

 

[Brad93]

Yep add some heat to the mix.

 

[Toleman]

Heat and impact screwdriver doing nothing other than rounding off the screws.

I’m going to try and post it off to you tomorrow @Richard.
Not managed to remove that bearing. I will deal with it if a problem arises after

I’m considering doing my test this year and going for a ktm exc. how do the Germans compare to the Japanese?

 

[Richard.]

That’s fine mate. I’ll do my best to avoid damaging it with heat.

 

[roofman]

RE..bearing retainer screws, direct local heat will overcome any loctite type thread retainer rather than killing the screw heads...also a good quality impact screwdiver with the correct fitting bit will get any OEM fitted screw out of anything...Iff i get a PM off Richard or Toleman with an address ile send the kit out

 

[Richard.]

RE..bearing retainer screws, direct local heat will overcome any loctite type thread retainer rather than killing the screw heads...also a good quality impact screwdiver with the correct fitting bit will get any OEM fitted screw out of anything...Iff i get a PM off Richard or Toleman with an address ile send the kit out

As toleman is going to be sorting the post costs pm him . He has my address if he wants to arrange to come directly to me. Thanks mate.

 

[Richard.]

Ok so I got this yesterday and I have to say for a tiny crack it has got to be one of the most rotten disgusting castings I’ve ever struck up on. VERY PORUS. .
We got there though.
Stage 1 was to open the crack up with a sharp file. Then I decreased it, cleaned it up and had a small prep ready for filling up.

Stage 2 warm her through. I was very aware of the bearings in place and chose not to mess with it so I went a bit light on the pre heat and took her to 60° held it for 30mins.
Then stage 3 welding.
It was spitting and bubbling but we got there. I had to build it right up to get something that resembled a metal and although it completely sealed the crack and looks quite clean there are still a couple of tiny pores that just have to remain. It’s got a chunk more metal in the area now so I can see it been a long lasting repair. Still needs tapping out mind those threads are knackered
@Toleman are you tapping it out or am I.

 

[Toleman]

Richard you are the man. I’d very much appreciate if you could tap it. I sent your address to @roofman a few days ago but not had a reply yet. Hopefully he sees this post.

I’m very pleased and thank you so much for taking the time to post pictures and a write up.

Once tapping is sorted if you can pm me a time and date that suits you for collection, the total bill and what your tipple is.

Chris

 

[Richard.]

Your most welcome mate.

 

[roofman]

Sorry lads ive been away a few days...ive sent Toleman a PM, is the kit still needed from me to take the plug a size bigger (new plug supplied)

 

[Richard.]

Sorry lads ive been away a few days...ive sent Toleman a PM, is the kit still needed from me to take the plug a size bigger (new plug supplied)

Prob not now mate. We are going m14 1.5.