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Dirt Bike Chassis Rust Repair

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  • Dirt Bike Chassis Rust Repair

    Today I started restoring an old Yamaha YZ 125.
    The bike was ridden near the saltwater I think from the rust in the sub-frame.
    Sanded off the paint, filed, chipped and generally removed rust scale to reveal the extent of the problem.
    Two holes joined by a small bridge.

    Ji
    Attached Files
    Grip it and Rip it

  • #2
    I ran a bead to try and find some solid steel around the holes.
    When I saw sparkles shooting out of the pool I changed direction away from the hole until I had a bead all around both holes.
    Then it was just a matter of a spiral bead pattern until the holes were closed.

    Ji
    Attached Files
    Grip it and Rip it

    Comment


    • #3
      The proof is in the tasting they say.
      Ground/sanded the beads down to see if there were any inperfections.
      Yes there are a few that need another TIG but not bad for a first run keeping in mind the size of the holes.

      Ji
      Attached Files
      Grip it and Rip it

      Comment


      • #4
        Do you think it would have been better to replace the whole section?
        Kemppi Pro Evolution 4200
        Kemppi 530 wire feed with MXE panel
        Kemppi ProCool ( coming soon)
        Cigweld TransMig 210se
        Cigweld TransTig 200 AC/DC
        Hypertherm PowerMax45
        CutSkill O/A setup
        Speedglas 9000x adflow
        Speedglas 9100xx

        Comment


        • #5
          Hi Larry,
          Well the tube is CrMo and that is hard to find where I am.
          The tube also has two bends which is another problem to get right without squashing it.
          There are also two complicated brackets on it. These could be cut off and reused but I would have to make a jig to get them back on in the exact position.

          This tube is part of the sub-frame and only holds up the seat.

          Ji
          Grip it and Rip it

          Comment


          • #6
            Cool dude. If its only a sub frame suport for a seat, no probs.

            Was a little hard to tell without a bigger pic.

            If you need small pieces of Cro-Mo, let us know and i might be able to help you out. Will send to you.
            Kemppi Pro Evolution 4200
            Kemppi 530 wire feed with MXE panel
            Kemppi ProCool ( coming soon)
            Cigweld TransMig 210se
            Cigweld TransTig 200 AC/DC
            Hypertherm PowerMax45
            CutSkill O/A setup
            Speedglas 9000x adflow
            Speedglas 9100xx

            Comment


            • #7
              Hi Larry,
              Thanks mate.
              It is hard to get up here.
              Bending tube is the trick, no one up here will do it.
              They only have building product size dies like 76 diameter and up.

              Ji
              Grip it and Rip it

              Comment


              • #8
                Yesterday I spent some time drilling out contaminants, welding and smoothing the rusted tube.
                I also drilled some test holes in other parts of the tube to see if it was structurally sound.
                Yep all good ready for paint.

                Ji
                Attached Files
                Grip it and Rip it

                Comment

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