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Repair options for case damage?

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    Repair options for case damage?

    Ok, 1981 1100E and still going over the bike making a list for things to do, buy etc. Took off the side cover to find 2 of the 3 bolt mounts had been over tightened by someone and broke a couple bits off the case side threaded mount points. The bolts were still holding fast with the missing pieces but I want to better this situation as well as do away with the piece on the one mount that is open to the outside.
    Any opinions? I have been thinking mabey building these 2 spots back up with some JB weld perhabs?? Open to ideas. Thanks guys.
    Attached Files
    -1981 Suzuki GS1100E
    -1975 Honda CB400 Super Sport
    -1981 Vespa P200E
    -1990 Ktm 540 dxc
    -1982 Ktm 495
    -1981 Ktm 495
    -1989 Atk 406
    -1987 Cr 500R
    -1982 Yz 125

    #2
    Here's a couple more pics
    Attached Files
    -1981 Suzuki GS1100E
    -1975 Honda CB400 Super Sport
    -1981 Vespa P200E
    -1990 Ktm 540 dxc
    -1982 Ktm 495
    -1981 Ktm 495
    -1989 Atk 406
    -1987 Cr 500R
    -1982 Yz 125

    Comment


      #3
      And last....
      Attached Files
      -1981 Suzuki GS1100E
      -1975 Honda CB400 Super Sport
      -1981 Vespa P200E
      -1990 Ktm 540 dxc
      -1982 Ktm 495
      -1981 Ktm 495
      -1989 Atk 406
      -1987 Cr 500R
      -1982 Yz 125

      Comment


        #4
        Hopefully, the PO didn't do the same to any covers that are suppose to keep oil inside the engine. Whatever you can do to just make sure the cover doesn't fall off, and that nothing flies in there and interferes with your ignition mechanism. It's electronic so shouldn't be as bad as if it was open points.
        Rich
        1982 GS 750TZ
        2015 Triumph Tiger 1200

        BikeCliff's / Charging System Sorted / Posting Pics
        Destroy-Rebuild 750T/ Destroy-Rebuild part deux

        Comment


          #5
          Thanks Rich, had the clutch cover and stator cover off and all is good there....havent adjusted valves yet, lots of silicone where a gasket should be and my only oil leak as well. I think it just needs a good gasket there but we shall see.
          Back to the case repair I'm wondering if I had the bolt in the hole and JB welded around it on the broken side if the JB would bond to the bolt after it cured or would I be able to back the bolt out afterwards....
          -1981 Suzuki GS1100E
          -1975 Honda CB400 Super Sport
          -1981 Vespa P200E
          -1990 Ktm 540 dxc
          -1982 Ktm 495
          -1981 Ktm 495
          -1989 Atk 406
          -1987 Cr 500R
          -1982 Yz 125

          Comment


            #6
            Clean the areas you want to repair immaculately with brake cleaner. Put a light film of Vaseline on the bolts, screw them in so there are a few threads past the last area that is broken. Glob on some JB Weld. Might want to use the "quick" formula, as it sets up a LOT quicker.

            And get some proper bolts. Those two with the straight slots belong in the garbage bin.

            .
            sigpic
            mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
            hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
            #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
            #2 son: 1980 GS1000G
            Family Portrait
            Siblings and Spouses
            Mom's first ride
            Want a copy of my valve adjust spreadsheet for your 2-valve per cylinder engine? Send me an e-mail request (not a PM)
            (Click on my username in the upper-left corner for e-mail info.)

            Comment


              #7
              Originally posted by Steve View Post
              Clean the areas you want to repair immaculately with brake cleaner. Put a light film of Vaseline on the bolts, screw them in so there are a few threads past the last area that is broken. Glob on some JB Weld. Might want to use the "quick" formula, as it sets up a LOT quicker.

              And get some proper bolts. Those two with the straight slots belong in the garbage bin.

              .
              Excellent on the Vasaline! I was thinking that may be a possibility and you just confirmed it for me!
              As far as the bolts go I am already planning for a new bolt kit for all the side covers for sure.
              Thanks for the reassurance
              -1981 Suzuki GS1100E
              -1975 Honda CB400 Super Sport
              -1981 Vespa P200E
              -1990 Ktm 540 dxc
              -1982 Ktm 495
              -1981 Ktm 495
              -1989 Atk 406
              -1987 Cr 500R
              -1982 Yz 125

              Comment


                #8
                The JB Weld will probably work, but if it doesn't they could be alloy welded up. Such a pair of trivial repairs are a lunchtime job for a good welder and won't cost more than a crate of beer.
                ---- Dave

                Only a dog knows why a motorcyclist sticks his head out of a car window

                Comment


                  #9
                  Thanks for all the input. As a follow up the JB Weld worked fine, I decided to go with the traditional JB over the Fast set JB as the Fast Set is 3000 psi strength vs 5000 psi on the other.... I'm satisfied with it, on with the rest of the bike!
                  Attached Files
                  -1981 Suzuki GS1100E
                  -1975 Honda CB400 Super Sport
                  -1981 Vespa P200E
                  -1990 Ktm 540 dxc
                  -1982 Ktm 495
                  -1981 Ktm 495
                  -1989 Atk 406
                  -1987 Cr 500R
                  -1982 Yz 125

                  Comment


                    #10
                    Thanks for the follow-up.

                    I was suggesting the quick formula so it would set up a bit quicker and not puddle. I was not aware of the strength difference, but I am aware of a difference in heat rating. I think the quick version is only rated to 450°, the regular formula is good to 550°. Either one would be good on engine cases, so I did not bring that up.

                    .
                    sigpic
                    mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
                    hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
                    #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
                    #2 son: 1980 GS1000G
                    Family Portrait
                    Siblings and Spouses
                    Mom's first ride
                    Want a copy of my valve adjust spreadsheet for your 2-valve per cylinder engine? Send me an e-mail request (not a PM)
                    (Click on my username in the upper-left corner for e-mail info.)

                    Comment


                      #11
                      I have had good success with Quiksteel also for something like this.
                      David
                      1998 Suzuki Bandit
                      1978 GS750 gone but not forgotten
                      1978 GS1000 - gone
                      1981 GS850 - gone

                      Comment


                        #12
                        I saw this stuff demo'd at Sema - it worked really well, I think it would be a good alternative if the breaks were in a more critical spot (i.e. not in a dry area, I'd be more than happy with JB weld where you've used it.



                        1980 GS1000G - Sold
                        1978 GS1000E - Finished!
                        1980 GS550E - Fixed & given to a friend
                        1983 GS750ES Special - Sold
                        2009 KLR 650 - Sold - gone to TX!
                        1982 GS1100G - Rebuilt and finished. - Sold
                        2009 TE610 - Dual Sporting around dreaming of Dakar..... - FOR SALE!

                        www.parasiticsanalytics.com

                        TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

                        Comment

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