Welding a Motorcyle frame crack??

**bradler451** · 03-18-2010, 10:43 PM

I have come across a 636 ninja motorcycle for 500 bucks but it was downed and I wanted to ask if the 200pi would be an appropriate machine to begin tig welding this thing back together. This will be my first tig project. The frame is aluminum. the crack Is along a factory weld. The aluminum is about 1/8 to a 1/4 inch thick. My question Is I want a clean weld what are some tips with gas and using the peddle for the end of the welds. I know I might get some discourage comments on that like u must start out smaller on ur project. I understand thanks

But I can pick stuff up pretty easy and i has messed around with a tig just never completed a project. I dont if any one has every did this before please help to guide my novice ass in the right direction thanks!!

**jbman45** · 03-19-2010, 06:22 AM

You won't have any problem with the machines capacity to weld I don't believe but you'll want to be pretty careful before you start on the actual frame to make sure of a couple of things. Mostly get some advice on the right rod to use since you really need an expert to tell you what type of frame metal it is. Could be some form of magnesium/aluminum alloy that would be very different to weld. Maybe check with the bike mfg. I have welded for years but some of the specialized stuff I really don't like taking a chance on, sort of like I can buy dental picks and tools for my shop but doesn't make me a dentist! couldn't really see too well on the photo the break but you may have to use some support stock in the repair as well. When I've gotten stuck and wasn't sure I sometimes check the local adult education campus and talk to the welding instructor there, they are pretty often willing to give out some guidance but got to be careful as lots of so called 'experts' really don't know squat. Applies to local weld supply stores as well! Would be ideal if you could find some similiar at a junkyard to try first. Good luck!

**robrob** · 03-19-2010, 12:33 PM

If you want a decent looking weld you're going to have to practice on Aluminum before you put the torch to the bike's frame. Your best bet would be to bribe an Aluminum welding expert to come over and do the welds that will be visible and try to learn as much as you can during his work.

**torqueman** · 03-19-2010, 03:50 PM

+1 what robrob said. Many of these bikes are made from pretty high tech aluminium and you really need to know what you are doing. Also after being wrecked that bad how do you know it will track straight? Not only do you need an welder, preferably with aerospace experience, but I would seek out a place that worked on these frames a lot to be sure it is straight.

My Goldwing has that high tech aluminium and was recalled by the factory a couple of years ago. It seemed that the frame was made by another company. At first Honda was letting them do the necessary welding but to save money they brought the welding in house. Well the guys on the line did not really have a lot of experience with this kind of welding. Several people had frames crack. When I took mine in for the recall, to be rewelded, I insisted on meeting the welder and talking about his credentials. Come to find out his day job was with Boeing and had a lot of experience in aircraft aluminium. Anyway he did an amazing job. Beautiful welds and probably 3 times thicker than the original welds.

**Bikespot** · 03-20-2010, 12:41 PM

I'm sure it will work for this. But you need the skills not the machine.

**matteh99** · 03-20-2010, 01:33 PM

The other thing is making sure the frame is straight and that nothing else is bent. If you are just puttering around it would probably be fine but if you are racing round the bike may handle weird.

Eric

**jakazz** · 07-22-2010, 11:42 AM

Junk the frame, any stresses that were incured in the accident wont show up. Aluminum will break, where steel will bend. If there is damage you will not be able to see it. As all mountain bike companies will tell you if you crash one of there bikes to hard they say junk the frame because aluminum will crack at just the wrong moment, where steel will not. You really need to talk to some "real" mortorcycle engineers about fixing this frame. This frame is a integeral part of the motor and drivetrain, its not just a weld up the hole kinda fix. This "fix" could cause serious injury or death if not treated right.

Hey but alas its a free country, do what you will, just dont ride near me, or sell the bike.

**SICFabrications** · 07-30-2010, 01:06 AM

i am in complete agreeance with jackazz!!! if you are asking if a machine can weld a motorbike frame, then obviously, you dont have the skills necessary to competently repair it. if the bike has been laid over and it adversely cracked a frame, that is a repair that I WILL NOT TOUCH and i am certed 4g nuclear on aluminum.... those lil plastic bikes run upwards of 100+ mph and you wanna chance a repair on the frame??? i used to young and stupid, but i was never that stupid.... send the bike to a pro, if he balks, then, cut your losses and walk.... if the pro takes it on, then i would still be leary... aluminum cracks, not bends and sometimes dychem wont even show you the extent of the damage.... save not only your life, but those around you, because my wife and daughter are on the road too....

**mountain eagle** · 12-05-2010, 11:23 PM

I've repaired a handful of salvage bikes over the years...... could be repairable but I'd need pictures at a minimum. If it otherwise runs and is okay, it's not too awful hard to just do a frame swap..... $500 is cheap.... or just part it out and then buy a bike with the profit.