Billet Aluminum welding and reinforcement

[Kurlon]

So... this lil piece of no-longer-obtainium, the externally adjustable timing cover got ground pretty badly in my crash. It basically wore just about through, deforming in the middle before exposing the timing wheel and crank end. At this point it won't take another hit without causing FAR more damage.



That's what it's supposed to look like. I'm thinking it needs a larger 'cap' welded over the remains of the center stub to provide a bit more of a surface to grind on should I crash again. Who should I see about getting this cover repaired and beefed up?

[Pigman]

What about having it machined and bolt on from the back a chunk of derlin as a slider instead of the metal...

[Kurlon]

It's a thought, I've got to see what there is for clearance/work room behind the cover. Anything's got to be more crashworthy than this buttery 'billet' though.

[xrocket21]

I think a competent welder could weld a new aluminum disc to the top of it, then a machine shop can machine it down to a lovely shape again.

Shouldnt cost more than an arm and a leg.

[rg500]

It shouldn't be to hard to weld a piece of aluminum to reinforce it. Billet is a lot easier to weld than a casting. No need to send it to a machine shop a little time with a grinder and file and it would look fine. I would offer to help but I am not so close and swamped with work. If you end up down this way let me know.

[Kurlon]

Fortunately I'm not in a giant rush, season is over and I'm not expecting to be on track until April next year. So I've got time to do this right. I *almost* have time to actually learn to weld so I can repair it myself, but not quite.

[jasnmar]

I *almost* have time to actually learn to weld so I can repair it myself, but not quite.

Are you trying to say it takes more than an evening? Ooops.

[Kurlon]

Are you trying to say it takes more than an evening? Ooops.

How hard can it be? You take a baseball card, press a banana to it and add electricity. Poof, structurally sound modern art.

[GingahNinjah]

Modify a woodcraft frame slider etc to fit over it and secure it somehow?!

[xrocket21]

How hard can it be? You take a baseball card, press a banana to it and add electricity. Poof, structurally sound modern art.

how hard can welding aluminum be, right?

[nhbubba]

The need to weld aluminum seems common these days.

[jasnmar]

Unlike the ability...

[nhbubba]

..or equipment.

[Rada]

I'm your huckleberry. PM me for details.

[jasnmar]

I may be handing you a clutch cover this weekend.

[Kurlon]

Will do!

[CBR929RE]

other option is to get a thick piece of steal. make a circle in the middle with 3 legs. here's my perfect CAD drawing of it for you to have Adam make it.

[jasnmar]

I'm not sure if Adam can manufacture to those kinds of tolerances.

[CBR929RE]

I'm not sure if Adam can manufacture to those kinds of tolerances.

Don't worry Tricky can clean it up

[Rada]

Is that a sex toy? I charge more to make those...

[carsick]

I charge more to make those...

Liability?

[Rada]

Testing

[nhbubba]

Ewe. Taking back my thumbs up.

[soofle616]

Everything you need to know about welding has already been said. But I would agree with the first response that a better solution is to put a replaceable slider on the outside. Drill two holes through the cover for screws to mount the slider. On the inside, use a countersink bit (or larger drill bit if you're a cheap ass) to create a countersink then bolt the slider on from the back with countersunk screws, no clearance required. You will probably have to put a bit of RTV or something on the screws during installation to prevent oil leaks. You could also drill and tap the holes and run the screws in from the outside but if you crash with that arrangement there's a good chance you'll grind the screw heads off so you'd have to drill and extract the screws to replace the slider.