Mike I have a KX250 case that needs that drain plug repair and the boss broke off that holds the pin that brings the shifter back to center. Not tech savvy enough to figure out how to DM you. Thank you, Gene
Sorry, I'm buried for the next several months at least and not taking on any more side work until I get caught up. I appreciate your thinking of me though and thank you for taking the time you watch. Mike
Years ago, I had a primary chain break and crack open my housing. I had no idea how to fix it at the time so I sold the bike cheap. Thanks for showing this.
Very well descriptive video learned a lot about my heat and my amps definitely tuning in to see more of your techniques just cracked the oil filter case on a 2012 Suzuki S 40 went into a little panic mode until I watched your video very helpful and descriptive thank you for that you're a man who really knows his trade highly impressed
Just found your channel. Subscribed. Truly impressed with your skills! I will be telling my fellow builders about your channel. Thanks for your videos! J
I don't have a surface plate so I used a big old mirror. (thick glass, plywood backing) and taped some wet dry to it only on one end. (it won't buckle the paper, but your strokes can only go one way) Then put soapy water on it . I used this setup to save from having to buy a water pump for my 5.9 Mopar. Because every penny counts and anyway I'm a cheapskate. It seemed to take forever but I finally got a gasket surface. Good information on your channel. Thanks for posting it.
Super impressive. I weld piles of cases for guys. I wish I had the machine shop access like you do, unfortunately space and funds just aren't there 😂. Welding old oil soaked cast aluminum is an art.
zmotorsportsjkur@gmail.com I don't quote prices because I generally have to see the item as I've gotten burned in the past. I am in northern Utah and did side work when I have time. Thanks. Mike
Was only here for any tips to repair a racing mower gear box but oh boy you grab my full attention and sub something tells me you would have a good go at this without all the fancy equipment if only the workmen ship here in the uk was as good 😎👍
Just follow the process that I outlined and you should be fine if you are familiar with welding aluminum. Also keep in mind that not all cast aluminum is created equal as some have more porosity or less porosity than others so some adjustments on the fly are often required. Good luck in the repair and don't rush it. Thank you for taking the time to watch. Mike
Ya, I enjoyed this thoroughly. Cant believe the dickhead who commented on your choice of words of all things. Why dont we critique his videos...oh nevermind, we cant. Lol great job my man, nice shop!
Thank you. I appreciate you taking the time to watch and especially for the comments. I don’t get some people with their comments but I appreciate your feedback. 🤔 Mike
Thank you. I have a Precision Mathews PM1340GT lathe. I have a full review of it way back in my video library. It was one of my first videos on TH-cam. I also have a review video for my PM935TV milling machine about the same time frame. Thank you for watching. Mike
There's not many engineers who can do what you do Mike i.e. diagnose, weld and machine to a very high standard. Wish you could do some welding on my honda cb900 crankcase. But I live in the UK and a long way away.
Great video! Do you have a hard time seeing the puddle while tig welding. Do you have any tips on helmet selection. Right now I have a Miller elite that came with the welder. Thanks
Thank you. I’m not a big fan of the digital helmets. I realize they have a huge following and are all the rage but I still prefer a fixed lense. I don’t really like tools that require batteries for some reason although I do have a Miller Big Window Elite that my wife bought me about ten years ago but I just use it in tight spaces when I can’t flip my fixed lense helmet easily. I use a #10 gold lense with a clear protective lense in front on both of my fixed helmets and can see very well. I’ve found that the gold lense seems to reflect some of the light back into the work. Thanks for taking the time to watch. Mike
Thanks man, fun watch! I have a dented & cracked case on my RM250. Ignition side, on the bottom close to the cover. Not sure its repairable, kinda thin right there. If I posted a quick vid to my channel could you lend your advice? BTW - Nice Shop!
Thanks for the comments. Sorry for the delayed response. If you want to post the video I will take a look at it next week when I have time. Thanks for watching. Mike
@@zmotorsports62 Hi Mike, thanks for taking a look! Here is the link th-cam.com/video/sbBQPCZy9EU/w-d-xo.html Super cool to watch you work, technical, clean, and precise. I used to work in a bronze art foundry back in the day, did a lot of TIG welding on large monuments (not so technical, clean, or precise). Even helped with the MGM lion in Vegas right before I got fired :) I blame the girl. Good stuff amigo.
Thank you so much for making a well produced video and explaining your thought process. I have used WD40 with my carbide burrs on aluminum. I looked at the Formax products and there seem to be different types available. Can you tell me the type you use? Thank you so much.
Thank you for the comments. I have been using Formax F-200 for many years. However, I recently tried CRL Tube Wax and actually prefer that, especially on abrasive discs, but also on rotary bits. Mike
Cut a slot out of the side of the drain plug boss, so its possible to get in to weld up the drain hole. Weld the drain hole up using mixed AC/DC wave form, then machine down the weld flat, drill and tap the drain hole. Takes a 1/4 of the time of messing about like shown on the video, welds arent riddled with inclusions, and the case doesnt get distorted due to the large amount of heat put into it.
I’m doing it, the three quarters tang for the return spring broke “that’s cheap” three quarter of material wide by three inches high and was only like a couple sixteenths thick “just a tab” for an arm off the back of like a,,,,,,, fork return piece. kick shaft return
Was curious on two things Sir, what Formax grease is your tube that you had used on the carbide Burr tool? Formax has different item numbers Also, after you applied the dycem, you sprayed some type of lubricant on the sandpaper.. what did you spray on the sandpaper and what grit did you use for the aluminum? Thank you very much very informative video I appreciate it ! I definitely would love to invest in some of the machinery that you have I just have welding equipment no , Mills or lathes.. unfortunately I can't do repairs as precise but thank you
Thank you for the comments and for taking the time you watch. I am glad you found it informative. As for the Formax, it is #200 and the grit that I used on the surface plate was 220-grit. For lube on the surface plate I just used some JB-80 Liquid lubricant. I don't necessarily think the lube matters all that much, the JB-80 was what I had readily available but I do find myself using it quite a bit for things like this. Mike
I'm in the process of repairing my cases off of my yz250 after a connecting rod let go and cracked the bottom front of both sides as well as gouging the inner perimeter of the case where the crank is. I have had success so far with depositing clean Tig welds, now am going to clean up the inner perimeter first with a die grinder. I then plan on taking the mating surfaces close to flush with a file as I don't have access to use an end mill like you did. What would be best for finishing it off once I get it to within 1/16" of flush with the file? Keeping in mind that this is the mating surfaces of the crank on a 2 stroke with no gasket.
Whenever I repaired a case at the split where the case halves met I used I file like you then when I was within about .020”-.030” I would apply bluing and lap the case halves on my surface plate, but any large flat surface would be sufficient. Best of luck and thanks for watching. Mike
@@zmotorsports62 as I'm not a machinist by trade abd don't have experience with lapping, what kind of sand paper did you use in the video? And what fluid did you lubricate it with?
I used some 220-grit followed by 400-grit wet sandpaper to lap the case half. I used some WD-40 as lubricant if memory serves and move the case in a figure 8 until all bluing was gone.
No issues as long as you don’t camp out with the welder. There’s plenty of webbing and support in the case plus the aluminum dissipates the heat so quickly it hasn’t been an issue. Although when I was doing a lot of the Yamaha Banshee cases back in the 90’ through 2000’s when they’d lose a chain and blow the countershaft out and wrap the sprocket into the mix, I would bolt the cases to help with keeping the countershaft aligned and running true when welding back together. I also lap the case on the surface plate when complete to ensure a flat sealing surface. Thanks for watching and hope that helps. Mike
I have an Rm85 (2 stroke) that has a hole on the very edge of the crankcase (where the two crankcases meet a gasket) I hope that makes sense. I was planning on trying to repair it with jb weld but I now know that’s not very wise. Should I just cut my losses and take the motor apart, send the crankcase in now? Or should I try to fix it myself with the jb weld? I appreciate the knowledgeable video, stay safe
Personally I have not seen much success using JB Weld. I know a lot of people use it and have heard of mixed success but I have the capabilities to fix it the proper way by welding and machining so I opt to go that route. I've had to remove a lot of JB Weld by the time it comes through my door over the years if that's any indication. Good luck and thank you for taking the time to watch. Mike
@@zmotorsports62 Since I’m young and broke, I figured I’ll try to patch it myself, if I can’t fix it myself I’ll reluctantly send it in somewhere. Thanks for the luck and for the information, you are awesome. Stay safe, Dominic
Hi Mike! Amazing work man. That was awesome. I’m in NC as well and have a similar crank case problem. How could I reach out to you for your business? What’s your website or Facebook?
Are you referring to a threaded boss? If so, in those applications UCD machined a new boss roughly the same size as the one cast into the case. Then before cutting the damaged boss off of the case built a small fixture to hold the new boss in the correct position for welding. Cut the damaged boss off and weld the newly machined boss in its place. I hope that is what you were asking. Thanks for taking the time to watch. Mike
Mike, do you do these repairs commercially? I have a clutch side trans case from a quite rare 1971 Carabela 125 MX bike. One of the collars that holds in a gear bearing in, is broken cleanly all the way around. At some point, before I got it, someone attempted to repair with a globs of what looks like white JB WELD. Would love to get it repaired. You seem to have the patience and care to do it properly. Thought I’d ask.
Hard to see it in the video but Ive gotta ask.... Does the slug you pressed in stand a little proud on the inside of the case??? If so wouldn't this prevent a full draining of the case when the plug is pulled?
No, the insert is flush with the inside of the case. I also blended it a little with a rotary bit before sending it back to the owner. Thank you for taking the time to watch. Mike
It’s possible as long as you could get it clean enough and there aren’t any seals or other rubber/plastic near the weld area that could be damaged. Mike
Hey Mike I have a 2003 gasgas wild 300 hp that has a crack on the left case half from the top to the bottom of the case (chain popped of and slapped the case will I was 5th gear pinned) I was wondering if you might be interested in repairing it for me.
I have search for one on line but it's a very rare atv and they do not make cases for it anymore. I also used jb weld on mine but it didn't work just like you said
Hello Mike, that is a very good example of a case repair for sure. I have photos of the right side case to my Electra Glide that needs repair somewhat similar in nature to your work in this video. Is there any chance that I can forward these three or four photos to you for you opinion and thoughts that would come to mind once you view them. I believe that the case is repairable as long as close attention to every detail, just like what you show here in this video repair. Thanks for posting such a bitchin' video and opening up a door of possibility
Ok, I just read that you don't do much in repairs since you closed your doors in 2017. Actually I want to do the repairs on my own. I am asking if you could see what I see in the photos, which is, if it's a possible repair or not. That would boost my confidence a ton or bring into reality if its too much to ask for in performing the repairs. I tried searching for a replacement right side case for a 1991 FLHS and always land on pages the want to sell an S&S lower end for $4,500.00
I have a 2004 TRX450R that the cases are warped and creating a problem when putting the two half's together, they teeter when they are aligned together. I am wondering how much work will need to be done and if it is a costly fix? I have a lot of time/money into this bike and don't want to give up on it. Any help would be much appreciated. Thanks in advance.
If the warpage is too severe it may mean the cases are trashed. When lapping cases some material removal is acceptable but too much and it will reduce crankshaft and countershaft endplay creating a rotating assembly that is way too tight. I would suggest a little lapping at a time with test fitment to measure endplay along the way. Mike
That's what I'm afraid of, I bought one case half new from a dealer and the bike had no issues the first couple years and then out of nowhere the transmission failed as I was driving it, I was in fourth about to switch into 5th and there was no fifth gear it was like neutral so I geared back into fourth and tried to go right down to neutral but it wouldn't. It turned out that it ruined the middle shift fork and burned up a gear but after I got a new shift fork and gear I was putting it back together I noticed the warp issue. It doesn't look like a lot of material would need to be shaved off but I'm in a bit of a pickle and need an expert to look at it.@@zmotorsports62
I am buried at this time but if you're not in a hurry and can accept the shipping charges I would be happy to do it. You can email me at zmotorsportsjkur@gmail.com Thanks. Mike
@zmotorsports I had a crack on the inside of my dirt bike case that I had welded. I haven't put it together yet because I just want to be sure or at least more confident that it has a good chance at holding up. Is this something you'd consider looking at and potentially I could mail it to you for your expert eye on it? Or maybe a recommendation on someone who I can send this off to. Much appreciated in advance. I will pay for the work and shipping as well.
Hey Mike If you have answered this question I apologize but how can we get in contact with you to do some work? I have a cracked engine case off a Ktm 300 I would like to have repaired. Jack
Can you fix my case it’s a 2006 crf450r and it blow a connecting rod so it slapped the counter balancer and broke the hole shaft and the bearing keeper fell of I want to repair it because on eBay there cases for sale gust I don’t want a jb welded case for $500
I have several other large projects I have to get done but if you’re not in a hurry for it I’d be willing to take a look at it and see if it’s something I could repair. Mike
I'm sorry, at this time I am buried and I'm not taking on any additional side until I get caught up with what I have already committed to. Thank you for your interest and thanks for taking the time to watch my video. Mike
I am very active on either garagejournal.com or irv2.com where you could send me a private message. I think you can also email me via TH-cam by going to the “about” section and hit contact. Thanks for watching. Mike
Very nice repair. I currently have a cracked case I would love to have you fix it for me. If your interested I can send you pictures and maybe you could give me a price.
Sorry, I no longer have my speed shop. I just posted the video showing how to repair these cases. Thank you for your interest and for taking the time to watch. Mike
@@zmotorsports62 Thanks. What you did to fix that, is exactly what I need. If I use JB Weld just to hold me through riding season, does this really screw the machine shop in the repair?
Good work. Correct me if I'm wrong, but this repair was only worth it because it was for a friend, right? If this was a paying customer, it's gotta be cheaper to replace it than repair it.
Back when I had my business and was doing a lot of powersports work, a repair such as that would be approximately $125-$200 depending on extent of damage. I’ve repaired quite a few over the years where the sprocket on the transmission countershaft came apart and tore the side of the case out. Those required more time and therefore could potentially be upwards of $300+. Thanks for watching. Mike
Thank you for the comments. I am located in Northern Utah. For a repair such as this they run in the $100- $200 range sure to taking about 1.5- 2.5 hours depending on the extent of the damage. That particular case half was only the drain plug and relatively easy so $120. Thanks for watching Mike
Is there anyway you can give me a business name for you if I could get a quote from you or just explain what I would have done from you if you still do this type of work please.
I don’t have my business any longer but I still do some small projects for people from time to time. The easiest way to contact me is private message through garagejournal.com forum where I am quite active. Mike
In this video I demonstrate the repair of a drain plug in a cast aluminum motorcycle engine case, CORRECTION, I TALK ALOT ABOUT HOW TO REPAIR THIS BUT SHOW YOU NOTHING!
I've done a couple now for subscribers but I'm sure shipping costs outweigh finding a good local shop. If you really can't find anyone else and don't mind the cost of shipping plus the repair I guess we could make it happen. Thank you for taking the time to watch and comment. Mike
@@zmotorsports62 awesome, where do I send pictures of the piece needing repair? It’s an inner casing I was told it can be welded and told by others it can’t so I’m not positive but I can send you a few pics of it and even a video to show you the damage
I'm a machinist by trade too . You did a awesome job. I would of not done anything differently if it was my repair. That repair will last a lifetime.
Thank you I appreciate that. Thank you for taking the time to watch.
Mike
Mike
I have a KX250 case that needs that drain plug repair and the boss broke off that holds the pin that brings the shifter back to center. Not tech savvy enough to figure out how to DM you. Thank you, Gene
Sorry, I'm buried for the next several months at least and not taking on any more side work until I get caught up.
I appreciate your thinking of me though and thank you for taking the time you watch.
Mike
After watching this I am not afraid to fix my own. Good video. Thanks.
Excellent, very informative video and expert job of repairing oil plug hole! Thank you!
I appreciate the feedback.
Thank you for taking the time to watch and thank you for the comments.
Mike
the time you take, the attention to detail shows your experience, great work
Thank you. I appreciate that.
Mike
That was a beautiful repair! I hope your customer appreciates your no shortcut approach.
Thank you. I'm sure he appreciated the repair. I received great feedback on it.
I appreciate you taking the time to watch and for the comments.
Mike
Good workmanship! Thanks for sharing😊👍 It's all in the details.
Thank you. I couldn’t agree more about the details.
Thank you for watching.
Mike
Why have I not found your channel before? Your masterclass is awesome!
Thank you. Glad you enjoy the content and thanks for taking the time to watch.
Mike
Years ago, I had a primary chain break and crack open my housing. I had no idea how to fix it at the time so I sold the bike cheap. Thanks for showing this.
You’re welcome.
Thanks for taking the time to watch.
Mike
Very well descriptive video learned a lot about my heat and my amps definitely tuning in to see more of your techniques just cracked the oil filter case on a 2012 Suzuki S 40 went into a little panic mode until I watched your video very helpful and descriptive thank you for that you're a man who really knows his trade highly impressed
Thank you for the comments and thanks for taking the time to watch. Glad it was helpful.
Mike
Just found your channel. Subscribed. Truly impressed with your skills! I will be telling my fellow builders about your channel. Thanks for your videos! J
Thank you very much for the comments and for subscribing. Glad you enjoy my videos.
Mike
First class repair sir and Wow you have a VERY nice shop!
Thank you. I appreciate you taking the time to watch and I appreciate your comments.
Mike
Great video. Great talent. Thanks for sharing.
Thank you. I appreciate that and thanks for taking the time to watch.
Mike
Great job! What a clean shop!
Thank you and thanks for watching.
Mike
I enjoyed watching this, even though I'm not a weldor. I get the impression that you like to do this kind of work. :=)
Nice clean shop! Well done.
Thank you and thanks for watching.
Mike
Just stumbled across your channel and found this gem of a video
Thank you for the kind words and thank you for taking the time to watch.
Mike
Great Job Thanks for sharing
Thank you for taking the time to watch.
Mike
Nice work and thanks for the video!
Thank you and thanks for taking the time to watch.
Mike
Nice job Mike!
Thanks Quinn.
I appreciate you watching.
Mike
I don't have a surface plate so I used a big old mirror. (thick glass, plywood backing) and taped some wet dry to it only on one end. (it won't buckle the paper, but your strokes can only go one way) Then put soapy water on it . I used this setup to save from having to buy a water pump for my 5.9 Mopar. Because every penny counts and anyway I'm a cheapskate. It seemed to take forever but I finally got a gasket surface.
Good information on your channel. Thanks for posting it.
Thank you for watching.
Mike
Nice work, clean shop, great tooling!
Thanks for the comments and thank you for taking the time to watch.
Mike
Super impressive. I weld piles of cases for guys. I wish I had the machine shop access like you do, unfortunately space and funds just aren't there 😂. Welding old oil soaked cast aluminum is an art.
Thank you, I appreciate the comments and thank you for watching. Your right, oil soaked cases are not for the novice. 😄
Mike
where are you located and how much to weld a place on a 2002 kx250rt side case i can send you pics if you give me an address
zmotorsportsjkur@gmail.com
I don't quote prices because I generally have to see the item as I've gotten burned in the past. I am in northern Utah and did side work when I have time.
Thanks.
Mike
Mike
Excellent Repair
Carl Bullock
Newtown, PA
Thank you Carl. I appreciate that.
Mike
Great job with the repair. Some people are convinced that it can't be done. You just proved them wrong. Thanks for sharing this information
Thank you for taking the time to watch and comment.
Mike
My respect for this gentleman
Thank you and thank you for watching.
Mike
Great work Man👌
Thank you and thanks for watching.
Mike
Lovely work. Nice one.
Thank you and thanks for taking the time to watch.
Mike
Great work.
Thank you. Thanks for watching.
Mike
A very GOOD job!😊
Thank you.
Mike
That wrist rest bar bench clamp is awesome
Thank you. It gets used quite a lot. One of those shop tools that I should have made many years ago.
Thank you for watching and commenting.
Mike
Was only here for any tips to repair a racing mower gear box but oh boy you grab my full attention and sub something tells me you would have a good go at this without all the fancy equipment if only the workmen ship here in the uk was as good 😎👍
Thank you very much. I’m flattered by your comments. Thanks you for taking the time to watch and best of luck in your repair.
Mike
Nice clean job. Was thinking about attempting a small repair on my 49 triumph cases but I’m a little gun shy.
Just follow the process that I outlined and you should be fine if you are familiar with welding aluminum. Also keep in mind that not all cast aluminum is created equal as some have more porosity or less porosity than others so some adjustments on the fly are often required.
Good luck in the repair and don't rush it.
Thank you for taking the time to watch.
Mike
Great content dude i am also a fabricator by trade great job 👌
Thank you. I wish I was a fabricator or a machinist but I’m just a mechanic who’s expanded his skillset a bit.
Thanks for watching.
Mike
Ya, I enjoyed this thoroughly. Cant believe the dickhead who commented on your choice of words of all things. Why dont we critique his videos...oh nevermind, we cant. Lol great job my man, nice shop!
Thank you. I appreciate you taking the time to watch and especially for the comments. I don’t get some people with their comments but I appreciate your feedback. 🤔
Mike
God job sir👍
Thank you.
Mike
😁😁😁👏👏👏👍👍👍muito bom parabems um abraço.
Well done....
Thank you. I appreciate you watching.
Mike
NICE JOB✌🏻😁
Thank you and thanks for watching.
Mike
superb!
Thank you and thanks for watching.
Mike
Very impressed, nice job! What type of lathe are you running?
Thank you. I have a Precision Mathews PM1340GT lathe. I have a full review of it way back in my video library. It was one of my first videos on TH-cam. I also have a review video for my PM935TV milling machine about the same time frame.
Thank you for watching.
Mike
There's not many engineers who can do what you do Mike i.e. diagnose, weld and machine to a very high standard. Wish you could do some welding on my honda cb900 crankcase. But I live in the UK and a long way away.
Thank you John. I appreciate the kind words.
Thank you for taking the time to watch.
Mike
Great video! Do you have a hard time seeing the puddle while tig welding. Do you have any tips on helmet selection. Right now I have a Miller elite that came with the welder. Thanks
Thank you.
I’m not a big fan of the digital helmets. I realize they have a huge following and are all the rage but I still prefer a fixed lense. I don’t really like tools that require batteries for some reason although I do have a Miller Big Window Elite that my wife bought me about ten years ago but I just use it in tight spaces when I can’t flip my fixed lense helmet easily. I use a #10 gold lense with a clear protective lense in front on both of my fixed helmets and can see very well. I’ve found that the gold lense seems to reflect some of the light back into the work.
Thanks for taking the time to watch.
Mike
Hi Mike you just continue to impress me with every project I see you do. Great video.
Thanks man, fun watch! I have a dented & cracked case on my RM250. Ignition side, on the bottom close to the cover. Not sure its repairable, kinda thin right there. If I posted a quick vid to my channel could you lend your advice? BTW - Nice Shop!
Thanks for the comments.
Sorry for the delayed response. If you want to post the video I will take a look at it next week when I have time.
Thanks for watching.
Mike
@@zmotorsports62 Hi Mike, thanks for taking a look! Here is the link th-cam.com/video/sbBQPCZy9EU/w-d-xo.html
Super cool to watch you work, technical, clean, and precise. I used to work in a bronze art foundry back in the day, did a lot of TIG welding on large monuments (not so technical, clean, or precise). Even helped with the MGM lion in Vegas right before I got fired :) I blame the girl. Good stuff amigo.
Thank you so much for making a well produced video and explaining your thought process. I have used WD40 with my carbide burrs on aluminum. I looked at the Formax products and there seem to be different types available. Can you tell me the type you use? Thank you so much.
Thank you for the comments. I have been using Formax F-200 for many years. However, I recently tried CRL Tube Wax and actually prefer that, especially on abrasive discs, but also on rotary bits.
Mike
Thank you@@zmotorsports62
Cut a slot out of the side of the drain plug boss, so its possible to get in to weld up the drain hole. Weld the drain hole up using mixed AC/DC wave form, then machine down the weld flat, drill and tap the drain hole. Takes a 1/4 of the time of messing about like shown on the video, welds arent riddled with inclusions, and the case doesnt get distorted due to the large amount of heat put into it.
Nice
Thank you and thanks for watching.
Mike
I have a question about some work, is there a way I could get a hold of you? Awesome video by the way, makes me feel better about my bike ha
Sorry, I don’t give out email or phone openly but I’m on garagejournal.com quite a bit. You could send me a private message through there.
Mike
Hi great job, may i ask what sort of welding rod you use for this job ?
For many years I used 4043 but the last several years I've been using 4943.
I’m doing it, the three quarters tang for the return spring broke “that’s cheap” three quarter of material wide by three inches high and was only like a couple sixteenths thick “just a tab” for an arm off the back of like a,,,,,,, fork return piece. kick shaft return
Was curious on two things Sir, what Formax grease is your tube that you had used on the carbide Burr tool? Formax has different item numbers
Also, after you applied the dycem, you sprayed some type of lubricant on the sandpaper.. what did you spray on the sandpaper and what grit did you use for the aluminum?
Thank you very much very informative video I appreciate it ! I definitely would love to invest in some of the machinery that you have I just have welding equipment no , Mills or lathes.. unfortunately I can't do repairs as precise but thank you
Thank you for the comments and for taking the time you watch. I am glad you found it informative.
As for the Formax, it is #200 and the grit that I used on the surface plate was 220-grit. For lube on the surface plate I just used some JB-80 Liquid lubricant. I don't necessarily think the lube matters all that much, the JB-80 was what I had readily available but I do find myself using it quite a bit for things like this.
Mike
I'm in the process of repairing my cases off of my yz250 after a connecting rod let go and cracked the bottom front of both sides as well as gouging the inner perimeter of the case where the crank is. I have had success so far with depositing clean Tig welds, now am going to clean up the inner perimeter first with a die grinder. I then plan on taking the mating surfaces close to flush with a file as I don't have access to use an end mill like you did. What would be best for finishing it off once I get it to within 1/16" of flush with the file? Keeping in mind that this is the mating surfaces of the crank on a 2 stroke with no gasket.
Whenever I repaired a case at the split where the case halves met I used I file like you then when I was within about .020”-.030” I would apply bluing and lap the case halves on my surface plate, but any large flat surface would be sufficient.
Best of luck and thanks for watching.
Mike
@@zmotorsports62 as I'm not a machinist by trade abd don't have experience with lapping, what kind of sand paper did you use in the video? And what fluid did you lubricate it with?
I used some 220-grit followed by 400-grit wet sandpaper to lap the case half. I used some WD-40 as lubricant if memory serves and move the case in a figure 8 until all bluing was gone.
How do you feel about the case warping when welding on only one side while not bolted to the other side case?
No issues as long as you don’t camp out with the welder. There’s plenty of webbing and support in the case plus the aluminum dissipates the heat so quickly it hasn’t been an issue. Although when I was doing a lot of the Yamaha Banshee cases back in the 90’ through 2000’s when they’d lose a chain and blow the countershaft out and wrap the sprocket into the mix, I would bolt the cases to help with keeping the countershaft aligned and running true when welding back together. I also lap the case on the surface plate when complete to ensure a flat sealing surface.
Thanks for watching and hope that helps.
Mike
Hi Mike, do you do customer work? I have a Honda Z50 case that is matching number to my bike which needs case repair.
I do take on side jobs when time allows.
Thanks for taking the time to watch.
Mike
I have an Rm85 (2 stroke) that has a hole on the very edge of the crankcase (where the two crankcases meet a gasket) I hope that makes sense. I was planning on trying to repair it with jb weld but I now know that’s not very wise. Should I just cut my losses and take the motor apart, send the crankcase in now? Or should I try to fix it myself with the jb weld? I appreciate the knowledgeable video, stay safe
Personally I have not seen much success using JB Weld. I know a lot of people use it and have heard of mixed success but I have the capabilities to fix it the proper way by welding and machining so I opt to go that route. I've had to remove a lot of JB Weld by the time it comes through my door over the years if that's any indication.
Good luck and thank you for taking the time to watch.
Mike
@@zmotorsports62 Since I’m young and broke, I figured I’ll try to patch it myself, if I can’t fix it myself I’ll reluctantly send it in somewhere. Thanks for the luck and for the information, you are awesome.
Stay safe,
Dominic
I completely understand.
Mike
Hi Mike! Amazing work man. That was awesome. I’m in NC as well and have a similar crank case problem. How could I reach out to you for your business? What’s your website or Facebook?
I don't have my business any longer but do an occasional side job as time allows.
My email is zmotorsportsjkur@gmail.com
Thanks for watching.
Mike
What type of filler wire are you using Mike? - Great presentation by the way?
Thank you. On that particular engine case I can't remember if I used 4043 or 4943.
How would you go plug welding a stud hole in aluminum crank case so that it can be drilled and re tapped?
Are you referring to a threaded boss? If so, in those applications UCD machined a new boss roughly the same size as the one cast into the case. Then before cutting the damaged boss off of the case built a small fixture to hold the new boss in the correct position for welding. Cut the damaged boss off and weld the newly machined boss in its place.
I hope that is what you were asking. Thanks for taking the time to watch.
Mike
Man I wish I had your skills ....neat stuff
Thank you and thanks for taking the time you watch.
Mike
Mike, do you do these repairs commercially? I have a clutch side trans case from a quite rare 1971 Carabela 125 MX bike. One of the collars that holds in a gear bearing in, is broken cleanly all the way around. At some point, before I got it, someone attempted to repair with a globs of what looks like white JB WELD. Would love to get it repaired. You seem to have the patience and care to do it properly. Thought I’d ask.
For clarity sake.....by “collar” I mean, the little edge in the outside of the case, that prevents bearing from sliding out.
Thank you for the comments and viewing George.
I don’t do much work for clients since closing my business down in 2017.
Mike
zmotorsports Oh ok. Apologies, I was thinking the vid was new. BTW:Your work looks great! Thanks Mike.
Hard to see it in the video but Ive gotta ask.... Does the slug you pressed in stand a little proud on the inside of the case??? If so wouldn't this prevent a full draining of the case when the plug is pulled?
No, the insert is flush with the inside of the case. I also blended it a little with a rotary bit before sending it back to the owner.
Thank you for taking the time to watch.
Mike
Less of this 👄 and more of this ✊....good work
Hi do you heat the bike cases or just weld?
I don't pre-heat. Just prep, clean thoroughly and weld.
How about welding cast aluminum without tearing the motor down? Think you can get it clean enough from the outside to weld up a crack?
It’s possible as long as you could get it clean enough and there aren’t any seals or other rubber/plastic near the weld area that could be damaged.
Mike
Hey Mike I have a 2003 gasgas wild 300 hp that has a crack on the left case half from the top to the bottom of the case (chain popped of and slapped the case will I was 5th gear pinned) I was wondering if you might be interested in repairing it for me.
I have search for one on line but it's a very rare atv and they do not make cases for it anymore. I also used jb weld on mine but it didn't work just like you said
I would be interested in taking a look at it and trying to repair it.
My email is zmotorsportsjkur@gmail.com to contact me.
Thanks.
Mike
Hello Mike, that is a very good example of a case repair for sure. I have photos of the right side case to my Electra Glide that needs repair somewhat similar in nature to your work in this video. Is there any chance that I can forward these three or four photos to you for you opinion and thoughts that would come to mind once you view them. I believe that the case is repairable as long as close attention to every detail, just like what you show here in this video repair.
Thanks for posting such a bitchin' video and opening up a door of possibility
Ok, I just read that you don't do much in repairs since you closed your doors in 2017. Actually I want to do the repairs on my own. I am asking if you could see what I see in the photos, which is, if it's a possible repair or not. That would boost my confidence a ton or bring into reality if its too much to ask for in performing the repairs. I tried searching for a replacement right side case for a 1991 FLHS and always land on pages the want to sell an S&S lower end for $4,500.00
Fellow GJ Here
I have a 2004 TRX450R that the cases are warped and creating a problem when putting the two half's together, they teeter when they are aligned together. I am wondering how much work will need to be done and if it is a costly fix? I have a lot of time/money into this bike and don't want to give up on it. Any help would be much appreciated. Thanks in advance.
If the warpage is too severe it may mean the cases are trashed. When lapping cases some material removal is acceptable but too much and it will reduce crankshaft and countershaft endplay creating a rotating assembly that is way too tight. I would suggest a little lapping at a time with test fitment to measure endplay along the way.
Mike
That's what I'm afraid of, I bought one case half new from a dealer and the bike had no issues the first couple years and then out of nowhere the transmission failed as I was driving it, I was in fourth about to switch into 5th and there was no fifth gear it was like neutral so I geared back into fourth and tried to go right down to neutral but it wouldn't. It turned out that it ruined the middle shift fork and burned up a gear but after I got a new shift fork and gear I was putting it back together I noticed the warp issue. It doesn't look like a lot of material would need to be shaved off but I'm in a bit of a pickle and need an expert to look at it.@@zmotorsports62
Great work! Can I ship a crankcase for my Honda CR500 to you for some repairs? Anywhere I can contact you if possible? Martin, Norway
I am buried at this time but if you're not in a hurry and can accept the shipping charges I would be happy to do it. You can email me at zmotorsportsjkur@gmail.com
Thanks.
Mike
Cost of this particular job? Great work.
Thank you. I can't remember what I charged off the top of my head. About a couple hours of work so in the $160-$200 range.
@zmotorsports I had a crack on the inside of my dirt bike case that I had welded. I haven't put it together yet because I just want to be sure or at least more confident that it has a good chance at holding up. Is this something you'd consider looking at and potentially I could mail it to you for your expert eye on it? Or maybe a recommendation on someone who I can send this off to. Much appreciated in advance. I will pay for the work and shipping as well.
You can check the cases' mating surface easy enough with a straight edge and feeler gauges to ensure it is true and flat.
Hey Mike If you have answered this question I apologize but how can we get in contact with you to do some work? I have a cracked engine case off a Ktm 300 I would like to have repaired. Jack
My email is zmotorsportsjkur@gmail.com
Can you fix my case it’s a 2006 crf450r and it blow a connecting rod so it slapped the counter balancer and broke the hole shaft and the bearing keeper fell of I want to repair it because on eBay there cases for sale gust I don’t want a jb welded case for $500
I have several other large projects I have to get done but if you’re not in a hurry for it I’d be willing to take a look at it and see if it’s something I could repair.
Mike
Do you still do these repairs? I have a case with a fracture, its actually not as bad as the one you did in the video
I do on occasion when I have time. However, I am buried currently.
Thanks for taking the time to watch.
Mike
I have a cracked case on a 1979 Honda CBX. I want tonget it fixed. How can we connect??
I'm sorry, at this time I am buried and I'm not taking on any additional side until I get caught up with what I have already committed to.
Thank you for your interest and thanks for taking the time to watch my video.
Mike
Hello Mike, I really like your jobs. My motorcycle case needs some repairs. Can you assist?
Thank you. Sorry, at this time I'm buried with work and don't have time to take on any more right now, but thank you.
Mike
would you have interest in a 1986 Honda 250R 3 wheeler left side motor case - i need some expert welding help?
If I wasn't so busy and backlogged for several months maybe. Unfortunately I simply don't have time.
I have a rm 85 same exact issue as this video, how can i contact you?
I am very active on either garagejournal.com or irv2.com where you could send me a private message.
I think you can also email me via TH-cam by going to the “about” section and hit contact.
Thanks for watching.
Mike
How much will you charge to repair my yz250 drain plug?
Depending on just how bad they're damaged I generally charge $100-$200 as it takes anywhere from 1.5- 2.5 hours to do these.
Are you still doing case repairs? I have a case that needs repaired from chain damage.
I do occasionally when I have time. Currently I am quite backed up work though.
Thanks.
Mike
Very nice repair. I currently have a cracked case I would love to have you fix it for me. If your interested I can send you pictures and maybe you could give me a price.
I would be happy to look at it.
My email is zmotorsportsjkur@gmail.com
Mike
I have the same issue on my BMW 1200RT. How do I get a hold of you?
Sorry, I no longer have my speed shop. I just posted the video showing how to repair these cases.
Thank you for your interest and for taking the time to watch.
Mike
@@zmotorsports62 Thanks. What you did to fix that, is exactly what I need. If I use JB Weld just to hold me through riding season, does this really screw the machine shop in the repair?
It will add another level of difficulty to the repair so the machine shop may charge additional if it's been gooped with something.
@@zmotorsports62 can I ask what was the cost for the work you did in the video?
I can't remember that one specifically but most take a couple of hours or so. They run in the $200-$250 range normally.
Good work. Correct me if I'm wrong, but this repair was only worth it because it was for a friend, right? If this was a paying customer, it's gotta be cheaper to replace it than repair it.
Thank you. No this case was sent to me buy a viewer from back east somewhere.
Thanks for watching and for the comments.
Mike
How much does this repair cost thank you
Back when I had my business and was doing a lot of powersports work, a repair such as that would be approximately $125-$200 depending on extent of damage. I’ve repaired quite a few over the years where the sprocket on the transmission countershaft came apart and tore the side of the case out. Those required more time and therefore could potentially be upwards of $300+.
Thanks for watching.
Mike
How can I send you mine to get done.
I am very active on garagejournal.com and irv2.comb You could send me a private message on either of those.
Thanks for watching.
Mike
how do i contact you in regards to repairing my case?
zmotorsportsjkur@gmail.com
I must know how much you would charge for such a repair, you know your shit. Great professional repair. where are you located?
Thank you for the comments.
I am located in Northern Utah.
For a repair such as this they run in the $100- $200 range sure to taking about 1.5- 2.5 hours depending on the extent of the damage. That particular case half was only the drain plug and relatively easy so $120.
Thanks for watching
Mike
I have a quadracer that experienced what you mentioned about the chain. Can i ship my case over to you for repair?
Too bad the case savers are taken off
how much would this repair cost?
Please reference back about 6 comments or so as someone asked already.
Thanks.
Mike
Where are u Located ?
Northern Utah.
Wish you were near me I have a hole in mower engine block everyone’s scared to touch he’ll I don’t care if it fails again but at least try
Yeah, most shops won’t touch such repairs.
Thanks for taking the time to watch.
Mike
Is there anyway you can give me a business name for you if I could get a quote from you or just explain what I would have done from you if you still do this type of work please.
I don’t have my business any longer but I still do some small projects for people from time to time.
The easiest way to contact me is private message through garagejournal.com forum where I am quite active.
Mike
How can I contact you
I am quite active on garagejournal.com. You can send me a private message there under username zmotorsports.
Mike
My comment will be how much for a similar job
A job similar to this would be approx a couple hours so probably in the $150-$200 range.
Thanks for watching.
Mike.
In this video I demonstrate the repair of a drain plug in a cast aluminum motorcycle engine case, CORRECTION, I TALK ALOT ABOUT HOW TO REPAIR THIS BUT SHOW YOU NOTHING!
Tons of info and examples here. Maybe you should watch the video with your eyes open.
I am मिस्टिंग यू oil nut लेकिज यू problam कास्ट ripiyair
Anyone near wrexham uk doing this
How can I send my case over to get it welded up too, lol
I've done a couple now for subscribers but I'm sure shipping costs outweigh finding a good local shop. If you really can't find anyone else and don't mind the cost of shipping plus the repair I guess we could make it happen.
Thank you for taking the time to watch and comment.
Mike
@@zmotorsports62 awesome, where do I send pictures of the piece needing repair? It’s an inner casing I was told it can be welded and told by others it can’t so I’m not positive but I can send you a few pics of it and even a video to show you the damage
Send them to zmotorsportsjkur@gmail.com and I'll take a look.
Thanks.
Mike
How do I contact you?
What is it pertaining to?
@@zmotorsports62 I all so have a dirt bike case that has a hole in it
Sorry, I'm too busy right now to take on new work.
Thank you for taking the time to watch.
Mike
I can't stand jb weld. I causes such havoc when tigging.
Agreed.
Thanks for watching.
Mike
CAN I SEND YOU A KX250 CASE THAT NEEDS REPAIR
Sure. It may be a little bit before I can get to it because I'm buried but I can try to fit it in.
Mike
@@zmotorsports62 CAN I SEND YOU PICS OF MY CASE SO YOU CAN GIVE ME AN ESTIMATE THANX BY THE WAY WHAT STATE ARE YOU IN IM NEAR ATL GA
I am in Utah.
zmotorsportsjkur@gmail.com
Thanks.
Mike
Wow way over the top sorry
Thanks. Most of what we do in our shop we end up going over the top.
Thanks for watching.
Mike