Fixing engine covers with Durafix

[erik]

Ages ago (in september '06) I had an off in the corromandel and made a hole in the LH crankcase cover.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_9452e.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_9452et.jpg" border=0></a>

It had been in a slide at taupo before and I think my bike's previous owner might've damaged it as well, so I guess it did well to last that long. Anyway, I made a patch and DEATH_INC welded it on for me.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/Img_9466e.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/Img_9466et.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_0646e.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_0646et.jpg" border=0></a>

He said he had a hell of a time welding it on because the alloy has a high magnesium content, I think. The cover slowly seeped oil, on a long ride my boot got oily.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_0975e.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_0975et.jpg" border=0></a>

I aquired a spare parts bike with a cover in slightly better condition, but it had a few scratches, a couple of hairline cracks and the inside was marked from the end of the crankshaft bolt.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1067.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1067t.jpg" border=0></a>

[edit: post split into 3 to allow enough embedded images (they're only thumbnails so hopefully it's ok)]

[McJim]

Frankly I'm amazed that ol' bandit of yours is still running. Well done.

[erik]

I wanted to fix the cracks and reinforce it so it'd survive another slide. I made a bowl shaped patch out of 3mm alluminium.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1068.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1068t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1069.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1069t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1070.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1070t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1071.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1071t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1072.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1072t.jpg" border=0></a>

durafixed it on.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1073.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1073t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1074.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1074t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1075.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1075t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1076.jpg" target="_blank"0><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1076t.jpg" border=0></a>

swapped it for the old patched cover.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1077.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1077t.jpg" border=0></a>

That was all done on the 23rd of march this year.

[erik]

So on the 4th of april, I went to a trackday at Taupo to test it (ok, testing it was actually an accident):

<object width="425" height="355"><param name="movie" value="http://www.youtube.com/v/dxwz-Sa7l18&hl=en"></param><param name="wmode" value="transparent"></param><embed src="http://www.youtube.com/v/dxwz-Sa7l18&hl=en" type="application/x-shockwave-flash" wmode="transparent" width="425" height="355"></embed></object>

It worked a treat, the bike slid a fair way and the cover didn't break! It didn't even wear right through the 3mm ally patch. I was able to ride the rest of the sessions and then ride home afterwards (the gear lever push rod broke, but Meekey_Mouse gave me a spare RG150 one she had).

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1092.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1092t.jpg" border=0></a>

Just today, I've gone and put another smaller patch over the bit that ground away, it should be able to slide really far now before it wears through...

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1101.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1101t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1103.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1103t.jpg" border=0></a> <a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1104.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1104t.jpg" border=0></a>

Hopefully I don't get to test it.

The durafix is kind of weird stuff to work with. More like soldering than welding (steel anyway, I've never tried welding aluminium). Even just using a MAP torch, I noticed the cover starting to bubble in a couple of places, I guess from the magnesium content (or an air bubble in the casting?). My first attempt with durafix was to mend the clutch cover that I damaged at taupo last year, it'd cracked right to the edge. I tried to bevel the crack so that I could get the durafix to flow into it, but I think it was the wrong approach.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1023e.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1023et.jpg" border=0></a>

I should have just put the durafix over the top. It's sitting under the bench downstairs looking rather messy.

<a href="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1030e.jpg" target="_blank"><img src="http://i38.photobucket.com/albums/e118/edorp/durafix/IMG_1030et.jpg" border=0></a>

I was using a propane/butane torch from mitre10, now I've got a MAP torch that is a fair bit hotter and works better. Maybe I'll have a go at tidying it up one day (probably only if I really have to).

[erik]

Frankly I'm amazed that ol' bandit of yours is still running. Well done.

85,200km and counting :D

[CookMySock]

haha, funny video, dood.

DB