broken case half ...

[thewiz]

Today I undid the loosely-screwed-on left engine case cover to expose the timing marks to set up puttin' the head back on and low and behold; what did I find ?? .... a quarter-moon shaped chunk of the lower case half MISSING near the lowest cover bolt in roughly the 7 O'clock position. Why am I not surprised? I would take a pic if needed .... but the missing piece is about a third of the size and shape of a poker chip.

Now I do have another case, whether it is any good or not, I don't know but perhaps it might be. Question is: Have any of you had any experience repairing a case that has been broken like this? Is it even advisable?

Once upon a time, I JB Welded an ear of a Chevy trans back onto the case and it held great .... difference is that: then I had the broken part to put back; now there's just the hole ....

[randy]

How the hell did that happen?

[red bandit]

Years ago I thru a rod out the side of a boat motor. I JB'd the pieces I had back in place, I did have a couple holes the size of a pencil that I filled with JB, and it held for a couple years before I sold it. I would think JB would hold if it's not at a stress point ie: bearing/seal or bolt. Might want to JB a piece of metal over the hole, or maybe build it up a little at a time day by day.
The piece might be inside the case.

[thewiz]

Well, Randy .... I don't know. It's right at the spot that would be protected by the case guards which there were none of on the bike and I KNOW it's taken a shot in the left side. I have never ridden it. Was likely done and or (and covered up) by the PO who assured me that there were no problems anywhere like this. I don't want get started bashing, BUT, I relaxed my guard at the point when he told me he was a clergyman ... . Shoulda' known better because there have been lots of problems he failed to disclose or lied about. No way could he not have known this .... and maybe there's a simple fix .... we'll soon find out.

[Ken Talbot]

One of the sidecases on SWMBO's 'H has a patch made of JBWeld or some similar product. Whoever did it did not do a real pretty job, but it has never leaked or fallen out. One day I may get around to sanding it a bit to try to match the contour of the case, or not.

[TopCatGr58]

Hey Wiz,

The Timing cover is just a dust seal, no oil there! Aside from JB weld, there is some other stuff called MegaSteel or some such. It comes in a roll, you cut off a section of it, knead it together because it has 2 materials that when mashed together activates it, and it sets like coarse steel/iron or cast aluminum. You can mold it like putty, and put a little extra along the inside edge to help it hold onto the rest of the case. I used some to fix the motor housing on some old popup headlights on an old firebird I had. Also have used it to repair a broken float post....impervious to gas! You can find it at auto stores, but I've seen it at Walmart also! I think it's stronger than J-B Weld because it does have metal in it, it's not just an epoxy.
T.C.

[red bandit]

On the boat motor I talked about earlier, I filed and sanded the JB then painted, You couldn't see it after that.

[81xsproject]

The guy who gave me my bike got it from an impound yard after some guy tried to out run the police and ended up laying it down. The timing cover was totally thrashed and a chunk of the case was missing broken off, too. I just filled it in with JB weld, let it cure, and then filed it down. Still there 3 years later.

[prometheus578]

JBweld is still holding on the chunk of cylinder( that protruding cam chain channel above the tensioner) that I cracked off five years ago.

[thewiz]

Thanks again

Geez ... we've got the most of makings for a JB Weld commercial here, don't we? No actors either .... characters ... but not actors ... .... Somebody ... Quick ... call their agent!!

I looked at it in more detail and with a more open mind later yesterday evening. Once I had calmed down, I realized that it's not the worst problem I've ever encountered on this bike. I know that there's no oil in there so it's only a matter of keeping dirt and water out ... I can cut a little 'form' outa' some soft metal for the inside edge and JB it in place, and then, like Red Bandit says, begin to build up against that with some more JB or epoxy putty, as TC as suggested, until I get to the right height, then grind/sand the sealing surface flush. It'll work .... Once this bike gets OTR again, I'll feel like it really belongs to this group of guys here ... not me.

[JWSanders]

I have a couple of small missing spots on my cases too. I have had limited success with Alumweld on my bike, but then, I was using a small, bernzomatic oxygen/mapp gas torch.

Since then I have used alumiweld with much better results using a full oxy/acetalyne rig, but sadly, not on my bike.

I have made a nice solid router table frame with it though.



In my case the timing cover was "forcibly removed" and the bolts ripped gouges in the case at the mounting points. I filled the areas wth the alumiweld and tapped new holes for the mounting bolts. The bond isnt the best though. A large part of the wall underneath the timing case on my motor is still missing completely.

I'm going to try it on the motor again someday, and see if it works better with a real torch. It joined 1/8" aluminum easily and the welds are nearly as strong and good looking (when I finally got the trick of it down) as a real weld.