Cracked cross member on frame

[posplayr]

Looks like you would need to remove the exhaust and probably gas tank and oil and lay the bike over. Clean the area with a flap wheel and then dremel to get into the nooks.

Also disconnect the battery and harness grounds to the R/R, make sure the ground clamp for the welder is close to the welding location and see if a solid weld can be made. If it is too rusted it will probably just burn through and you would be SOL.

[Schweisshund]

Looks like you would need to remove the exhaust and probably gas tank and oil and lay the bike over. Clean the area with a flap wheel and then dremel to get into the nooks.

Also disconnect the battery and harness grounds to the R/R, make sure the ground clamp for the welder is close to the welding location and see if a solid weld can be made. If it is too rusted it will probably just burn through and you would be SOL.

Ok, thanks for the tips. If it doesn't work, I will start the long process of stripping down the bike and transferring it to another frame. (groans)

[posplayr]

Ok, thanks for the tips. If it doesn't work, I will start the long process of stripping down the bike and transferring it to another frame. (groans)

I has something similar: I had compelery striped my frame sandblasted and repainted and was going reassembly during a complete GSXR conversion including Bandit Swing arm. As I was remounting the rear shocks the mounting bolt broke off due to a poorly re-welded repair from a former PO.

I was close to apoplectic, but in the end, I shielded the bike and keep the welding clamp directly on the bolt and using my trusty $100 HF welder a new one was welded without damaging the paint too much.

[Schweisshund]

I has something similar: I had compelery striped my frame sandblasted and repainted and was going reassembly during a complete GSXR conversion including Bandit Swing arm. As I was remounting the rear shocks the mounting bolt broke off due to a poorly re-welded repair from a former PO.

I was close to apoplectic, but in the end, I shielded the bike and keep the welding clamp directly on the bolt and using my trusty $100 HF welder a new one was welded without damaging the paint too much.

I have two other frames. One is completely stripped down to the bare bones and a section of the frame is badly damaged. The other is in near mint condition and I wanted to rebuild an additional bike using it. The one that is damaged has the exact center stand mount and cross member and that part is not rusted or damaged. I am thinking ..... Cut both cross members off, weld the good one to where the bad one was and keep the mint frame unmolested ???

it also appears it can be done without removing anything, but using a lot of shields. Some places will be a tight fit.

[Schweisshund]

I am going to inquire about this at a local muffler shop.

[Sandy]

Sounds like a plan. Some of these might help. Good luck with it.

http://www.dimecitycycles.com/catalogsearch/result/?q=slugs

[Schweisshund]

Alright .... Just got done talking to the owner ( he's a biker too ) and he is going to fix it for me Tuesday for $20- $30

[Schweisshund]

Sounds like a plan. Some of these might help. Good luck with it.
http://www.dimecitycycles.com/catalo...esult/?q=slugs

the owner of the muffler shop saw the picture and said it isn't a huge problem if it's rusted through. He said he has thick steel he could tack weld it into place (??)

[posplayr]

the owner of the muffler shop saw the picture and said it isn't a huge problem if it's rusted through. He said he has thick steel he could tack weld it into place (??)

Make sure you remove the grounds from the frame and battery so he doesn't fry your ignitor R/R or other electronics you have on board.

[mrbill5491]

Not sure I wouldn't just replace the whole tube there. Take off the exhaust, trim out that tube and weld in a new one. It can be beefed up some if you go that direction by inserting a smaller tube inside the new one and weld them together then reattaching to the rest of the frame. I would be bit leary if the PO owner can fix it for that kind of money and it be right.

[Schweisshund]

Not sure I wouldn't just replace the whole tube there. Take off the exhaust, trim out that tube and weld in a new one. It can be beefed up some if you go that direction by inserting a smaller tube inside the new one and weld them together then reattaching to the rest of the frame. I would be bit leary if the PO owner can fix it for that kind of money and it be right.

I asked the muffler shop owner about that - he advised against it. I don't understand the reason why. But, if things go right Tuesday, I will post pictures of the work he did.

[rustybronco]

http://i192.photobucket.com/albums/z180/schweisshund01/cracked%20cross%20member_zpsydzvwdsp.jpg

As it appears to me, the tube is bent. It would need to be straightened before being welded.

For $20~30 dollars, I doubt you will be getting much more than the crack being welded.

It can be beefed up some if you go that direction by inserting a smaller tube inside the new one and weld them together then reattaching to the rest of the frame. I would be bit leary if the PO owner can fix it for that kind of money and it be right.

You might be able to inset a smaller tube inside the existing tube before welding it. (Unable to ascertain from the picture provided.)

[JTGS850GL]

I'm not sure I would bet my life on that rusted tube. What you're seeing is only the visible outside damage. Until you remove the triple tree and see what going on you don't really know the extent of the damage. As Rustybronco said... It looks like the tube is not only rusted through but also fractured and bent. Might also indicate that other areas of the frame are out of alignment as well. I know it's hard to accept but, if it were me, I'd go ahead and swap frames.

[wymple]

Don't underestimate the abilities of a good welder. Just be sure he is one.

[Schweisshund]

Don't underestimate the abilities of a good welder. Just be sure he is one.

He has done work for me before - but it was years ago. What I thought was going to cost a couple hundred, he only charged me $40 - he welded the flex pipe back onto my exhaust. I will see how it goes tmw. If it looks like it could break - it will. I have to keep that in mind.