Hmm new idea??
Drill a hole and weld in a tube at 90deg like in the pic???
Drill a hole and weld in a tube at 90deg like in the pic???
If you use a slug, use a hollow (tubular) one.
A solid piece of bar is just too rigid, you'll probably get more cracking issues.
That's a nasty crack in a nasty place.
Suzuki should have known better than to design it like that.
Method 1 would probably make a better repair if you design it right, even if it looks terrible
Me, I would ask a welder.Anyone got ideas for best practices for fixing this frame??
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My ideas so far are 2 different options.
Option 1 - cut a notch in it and weld it, then cut some plates to weld over it on both sides to reinforce.
Option 2 - cut a window and drop in a slug, drill some holes, weld in the slug, then cover the window with a plate and weld it up.
And I guess option 3 would be both…
I’m leaning towards 2 but getting a curved plug may be difficult as I don’t have a way to heat and bend it, although I’m sure I could figure something out if need be.
It would seem the crack in this area was common enough that by the following year they added reinforcement in this area (like option 1).
Ideas? Thoughts? General ramblings about my wasting of time on this frame?
Well yes, and then again no.Me, I would ask a welder.![]()
Option 1 - cut a notch in it and weld it, then cut some plates to weld over it on both sides to reinforce.
I’m not a welder, so I have been chastised….Well yes, and then again no.
I'm a coded welder.
I work with 22 other coded welders.
Only about three or four of us would know how to make a strong and durable repair to that frame.
Some of them would be absolutely clueless believe me
That would be my choice if I were working on my bike. When I was a welder in a fleet garage and doing heavy equipment repair, I welded many a cracked truck or trailer frame and the method was always the same, V the crack out and weld it, grind it smooth and plate it. If you want you could drill a few holes in the plate and plug weld it, and if you wanted to go a step further you could even add a triangular gusset near the frame intersects. Repairs are stronger than you think, I’ve never seen one fail. Usually it’ll break somewhere else before a repair fails. Keep it simple!
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Suzuki should have known better than to design it like that.
Regarding welding .. The crack appears have started at the top side an continued downwards
If possible it would help to reinforce the top fibers having the highest bending stress
Probably
The internal pipe slug helps A weld without patch a la Mailman can crack, again and in one pop
Which is dangerous.
Dont know if this can affect the straightness of the frame
Yeah, I'd go with option 1 and add the gussets like bob suggested.
You using TIG or MIG? TIG would be my choice for that.
And I wouldn't bother V-ing the crack. There's just enough gap as it sits. Just run a bead around it and add the gussets.
Thought you might find this interesting,
https://bringatrailer.com/listing/1971-suzuki-t350-rebel-2/
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How's that T350 compare to your baby RD?