Delboy's Garage, Hayabusa 21, "Corrosion Disaster" !

Rolling nicely, making progress, then a Disastrous discovery..!
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[@mikebutler6292]

ouch !!!! after reading the comments below i think most peeps have missed the reasoning to your statement at the end , i watched it and could see that you were upset and well pissed of as like you say we have all been there and at that moment you hate eveybody and feel let down , Now in my experience , i as you have done talked to the guy in a calm and polite manner and sounds like hes a real nice guy and is helping you , fair play to him , if on the other hand you went at him full barrel then im sure the answer would have ended in an OFF !!!!! as you state nobody checks and cleans that deep into the engine so the seller was probably unaware of that , In a way ( not for you ) but its another interesting problem that im sure has happens to at least one of us and we can learn from it . Ideal accessorise for your garage del a punch Bag

[@Moonfleet41]

At last buddy, some understanding...! Exactly that, I've known the guy in question for many years, in fact, have known the shop long before he bought it, ie, the previous owners, and yes it was a crushing disappointment to find that heightened at the moment you find it, like you say, it's a natural knee jerk reaction, but this is YT and as you've probably worked out, you're blamed and flamed for everything you say, right or wrong... shallow people take great pleasure in stamping and trampling on msitakes in a frenzy of glee and triumph, but never take the time to apply a little understanding and empathy... fast forward 48hrs, have chatted with the guys, and we have a great solution... they have offered to have it ali welded by a local fram specialist if I chose to take it over to them.. .as it's such a great suggestion I've got a mobile guy swingin by for a look and in the meantime, I've stripped the pipes out and cleaned it up, and it looks a hell of a lot better than it did already.... Thanks for your comment Mike, someone who understands what it's like this side of the bench, take care and have a great weekend.

[@mikebutler6292]

@@Moonfleet41 Cheers

[@allenhumphreys2586]

Well on the video it looks like some real bad corrosion on the aluminum(aluminium?), it must be completely removed from surface before any welding is attempted, any contamination and weld won't work ? The welder will determine all that. Good luck !!

[@Moonfleet41]

@@allenhumphreys2586 Hi Allen, stripped the pipes out and cleaned it up a little today, (video for Tuesday), and it looks so much better now, the fluffy corrosion was on the surface, and the metal is solid and doesn't flex.. so im really confident...

[@allenhumphreys2586]

@@Moonfleet41 I sure hope you get shorted out, never owned a Busa, ridden plenty, but always had secret liking to them, I'm mostly a Kawasaki faithfull, saw my 1st Busa while riding my then new ZRX1100 in 1999 in the North Carolina mountains, beautiful two tone copper, we like to call them affectionately "Eyeabuser". Sorry to go off topic, looking fwd to more videos. :)

[@billyfriday]

The term freeze plug is slang, the correct name of the press-in plugs is actually core plug. It is mistakenly thought that the purpose of these plugs is to be pushed out and save the block from cracking if the engine has water in it and it happens to freeze. This is nothing more than an urban legend. The purpose of the plugs is to fill the holes that were made during the casting process, so the foundry could remove the core sand from the coolant passages. Saving the block from cracking in case of a freeze was never the manufacturer's intent for these plugs.

[@CwazyWabbits]

You are indeed correct.

[@garyjohnson4575]

Believed it for 40yrs.....thank you!

[@mikereed9047]

Sometimes they work! Had an old Sherpa diesel temperature got down to minus 20 coldest night on record for Monmouth core plugs popped block survived normally just a week point on old engines to rust and weep

[@billyfriday]

@@mikereed9047 a blessing in disguise. But not there purpose

[@Jo-hannson]

Yes sir

[@Turtlefaceful]

Ball head hex keys are terrible to use on stuck bolts. The chamfered edges reduces the amount of surface contact, and makes it more likely to strip out the heads.

[@Moonfleet41]

They weren't ball heads mate, straight sided... correct what you say though....

[@plageran]

My current problem with my front brakes self inflected

[@iaincochrane9392]

Perhaps I'm living back in the day, but in my day it was "no warranty given or implied", different if it was a newish bike, but an old timer like you've just bought, well, need I say more ?

[@Moonfleet41]

Quite right mate, but I think in these days of claims direct, dealers need to value their reputations, and they will stand by you, but it's important to conduct a respectful relationship with them, and don't take the piss, this is wear and tear, nothing more, yet he's already offered to have his local fabrication company weld it up for us... as I showed also, he's replaced both fork stanchions and hasn't flinched from any of the issues... but also, I've put over a grand in parts in to this bike already, all I went to the dealer was advice, guidance and a suggestion of a way round it, and that's what I got... but as I have to take the bike to him, quite rightly, then gonna get a mobile welding guy to drop round and take a look first... You're right also, the whole world of warranty is a minefield and so much of it is about courtesy, not legal liability... cheers for your input mate.

[@garya3056]

Moonfleet41 translation needed pls for this dumb old yankee, Del. What does “don’t take the piss” mean in this context? 🇬🇧🇺🇸 Cheers!

[@garya3056]

Mahatma618 For asking for a translation? Are you high?

[@MattRiddell]

@@garya3056 It means like don't try to take advantage of them. I mean more literally don't laugh at them or don't joke with them but I guess in this context he's meaning have a good relationship with them, come to them if there are problems but don't be like my bike ran out of gas so you have to fix it or the paint has a scratch etc

[@garya3056]

Matt Riddell much appreciated, Matt. 👍

[@oliverabdulov6437]

Used to work in the truckshop for a while, learned that when you deal with exhaust bolts/studs, a little impact gun and some of icing fluid, helps a whole lot, we used to work torx bits in and put some fluid on them and hammer them out with a little 3/8's impact gun. A 3/8 or 1/2" impact(battery or air both will work) might be a good addition to the collection.

[@Moonfleet41]

Cheers buddy, wise words well said, lithium impact gun has been on the list for a long time, but I keep seeing people strip bolts out with them and sometimes cause more problems than a simple hand tool, but in jobs like this they actually have a use!

[@HalfdeadRider]

I invested in an impact gun as I knew I was doing a Chain and Sprocket change, a couple bits of wood in the swingarm and the front sprocket was off in seconds. On rusted old exhausts, if possible and after a load of WD40 and left to soak/work in, lots of heat is usually the way to go. I'd try not to use an impact gun unless like mine it has different settings and a variable trigger, because that will snap them in a second if badly rusted and the gun does not have a variable trigger on low setting, but a very good tool to have, it saves a lot of time undoing nuts n bolts too.

[@oliverabdulov6437]

@@HalfdeadRider Agreed, we never used the 350NM 1/2" impacts for stuff like this, those were for the big 18mm bolts, otherwise that would obliterate more than it would wind out. But experiance has learned, if the sharp impact motion, combined with heat/cold and oil doesnt work, it wasn't gonna come regardless of what you wouldve tried. If they snap off on a accordingly powerd impact, they were stuck enough to be a lost cause to begin with. But a tip to maybe help with it (one of the seniors told me), alot of the bolts that break on impacts are due to the energy of the impact turning into heat(heats up the bolt but not the casing thus making it tighter), its important to dont hammer on them for too long in a row, give the bolt time to cool back off(either with air or the blueice), they can heat up enough to where it compromises the steel and they just twist clean off, afterall steel gets softer the hotter it gets, and hammering it for a minute straight puts quite the heat in them. He told me he usually does 15 secs of hammering before letting it cool.

[@HalfdeadRider]

@@oliverabdulov6437 Yep, some can heat up enough to snap too, but usually with on-off high torque guns, the sheer torque can just snap them before they even have a chance to heat up, especially on smaller rusted bolts. The torque is why you also do not wind fasteners/hardware in with high torque on-off guns, we always used them only on car wheels. With my impact drive/gun I can put it on the lowest setting (three torque settings) and be gentle with the trigger to wind them on and finish by hand tool, and torque wrench if used at all :) But mostly for small nuts and bolts I just use sockets or spanners.

[@oliverabdulov6437]

Ouch, Might be able to get that repaired by an aluminum welder, seek out a good one and ask him if he could possibly weld it back in place, these rings are just for holding the exhaust, no loadbearing or anything, so should be fine if he can lay a bead around the crack to keep it on its place and make so no gasses leak past the gasket in there. Biggest part will be either pulling the engine and then the head, though can be fun if you enjoy engine work, gives opportunity to inspect the cylinders etc. or have him weld it on the bike, but not sure thats a great idea. Regardless, best of luck, hope you can sort it out

[@Moonfleet41]

Cheers buddy, you are of course quite right, this is no more than welding a broken fin back on, the only hurdle is gonna be whether there is enough healthy metal to grind it back clean for TIG, gonna strip the pipes out tomorrow, clean up the area as much as I can, and he's gonna drop down on Mondey, see if he can do something with it... gonna take the easy steps first, fingers crossed!

[@Bikemech1]

You can use a sacrificial torx bit in rounded cap head bolts. They need a bit of persuasion with a hammer to get them in, but I have used them a number of times. Socket torx work a treat.

[@Moonfleet41]

Does indeed, but would you hammer anything near things like that cracked exhaust port, in fact, you shouldn't really hammer anything in to a cylinder head, it does work on chassis fasteners that can take the impact, but am just gonna gently drill these out... wish me luck!

[@Moonfleet41]

@@wolfdog7265 yeah of course.. so much actually can be achieved with some appropriate focused impact.. but as you'll know, so much can also be made worse.. i feel heart broken for guys i watch on the tube who apply a battery impact gun to EVERYTHING..even taking out fairing screws.. its like they have an aversion to using hand tools... and as you can guess.. you watch as they strip and round out fasteners that would have given no trouble what so ever with a simple hand tool..... but hey, we all learn with our mistakes aye... .Thanks buddy, yeah, ill get her done.!

[@danparsonage3884]

You kept your cool and didn't discredit anyone. Cool as a cucumber! Looking forward to the next video 👍🏼

[@Moonfleet41]

Thanks Dan, there's nobody to blame, corrosion is just life! ... ye cannae change the laws of physics Jim! 👍

[@danparsonage3884]

@@Moonfleet41 I have 5 studs soaking in WD because the 5mm nuts won't come off! Might have to invest in a new set!

[@ResidentWeevil]

Oh ouch, I feel your pain. This video is the best advert I've seen for replacing original steel header pipes on a bike with aftermarket stainless steel ones. I'm so glad I did this on my Fazer a few years back.

[@AdamHougham]

Hi Del - When my exhaust header bolts were stripped out like these four, I had a word with a pro mechanic who lives on my street for advice. He popped an impact torx bit onto an extenson bar into the holes where the allen holes once were, did a little percussive persuasion and they let go pretty easily. I've not got a set of 3/8s impact torx bits yet, but they're now on my list! Fingers crossed for a good fix on that worrying-looking crack. Take care mate

[@Moonfleet41]

Thanks Adam,.. that is indeed a good way to crack them and get them out.. im always investing in tool and equipment, and the list of stuff i still need never seems to get any shorter.. i guess thats why the Pro guys are always boasting (or moaning lol) that they have had to invest £30k in tools... A decent impact gun is on the list for sure..

[@CortinasAndClassics]

Jeez Del that's unfortunate, I hope the dealer can help you out with this problem. I was cringing when you were cracking the exhaust studs, one job I really don't like. I must get some of that spray for my ZZR the studs are still there lol.

[@kevinmasey6459]

As a long time motorcycle enthusiast with a twenty year old bandit ,I get a bit annoyed at the manufacturers,put bloody stainless bolts exhaust system etcetera ,charge an extra 100£ . When they advertise the new bike put that in the description,resale price would increase

[@kent6732]

kevin masey I’ve been slowly replacing my bikes bolts with stainless as I go along. For a dollar or two each it’s worth IMO.

[@neilchallis3203]

@@kent6732 if using stainless bolts with nuts always use dissimilar stainless A2 and A4 with copper grease

[@kent6732]

@@neilchallis3203 Thanks for the heads up.

[@eurosafeesgts1996]

Can't that just be welded up? I believe that doesn't seal to the exhaust header itself so if it where to snap off it wouldn't cause the exhaust to blow anyway.

[@Moonfleet41]

If it wasn't needed, then it wouldn't be there, it helps locate the exhuast, centrally over the port, which then holds the ring seal in, the exhaust is only held by a two bolt flange so the mount of this casting keeps it central... and yes, it'll be welded.

[@Moonfleet41]

@@malcellison8831 I paid for the welding.

[@ciaranmckeown4536]

Why didn't you use heat? Thought you were gonna snap your wrist with that T-bar lol

[@jamesweber4938]

Why not start the engine and see if it leaks exhaust gases at the crack. The flat end of the pipe should make a seal ? Does the pipe flange have a gasket where it meets the head ? Can you live without the part that is cracking off ?

[@Moonfleet41]

It doesn't leak, checked that already, you'd have heard a tick straight away, and it runs smooth and quiet... hoping the exhaust ring is well inside that crack area, I don't believe this thin aluminium mouth is any more than a locating casting, so yeah am hoping all we'll need to do is beef it up with some weld, don't think it's critical!

[@cr-ew8od]

Most excitement ive had on a Friday night for some time.

[@haroldwiser2641]

Tough break with the crack 😥 The sparks were s surprise for me! Have a great weekend D & P.

[@Moonfleet41]

Sure thing Harold, the sparks were a first time for me too, never seen that before! Have a great weekend Sir!... D&Px

[@paulharast1958]

As soon as you turn the light on I noticed the crack. It's a good thing you got a good eye and noticed that. And reading the comments it's a good thing they are going to fix it for you. And for me, every time I'm dealing with a rusty bolts or a nuts I will inspect everything around it before trying to loosen it. Penny & You Del Ride Safely And Have A Wonderful Weekend. God Bless And Keep Both Of You Safe.

[@Moonfleet41]

Hey Paul... Thank you as ever for your kind and supportive words.. the seller has thrown us a lifeline, and we have a plan to walk down now at least... back at it today, got to strip out the furniture in the way, clean up the alloy carefully. and i have a mobile welder guy coming on Monday to have a look.. im hopeful it will be a pretty easy fix and we can move in without too much drama.... have a great weekend and take care too.. all the b est my friend.. Del & Pennyxx

[@springy-2112]

Hey Bruv its a bind but she'll tig no worries !!👍🏻👍🏻☮❤

[@ShazyShaze]

Rough break, geez. Hopefully you can get it welded up to spec without too much pain!

[@Ratqueenbikes]

Aw what a shame and so unfortunate hun. I'm sure within a few days you'll have a plan. Great job despite the bad news x

[@Moonfleet41]

Hey RatCuz, Yeah, you know me, i have a cunning plan...whether it works or not is unimportant... projects are about the journey right..! Hope its warm and sunny in The Highlands, take care and ride safe...Yer Southern family... D&Pxx

[@Thumper1222]

Don`t let it beat you Del. Another honest and cool vid.

[@fantomthrashers7260]

Bummer del. Hope all goes well fella, mad to see this beast on the road.

[@Johny40Se7en]

It's been a while, been all over the place lately so have been just kind of collecting your videos for later. Rust is a proper pain in the arse isn't it. I bloody love that quote at the end and agree completely. My my persistence payed off turning my Mam and my sister vegan =) My Dad's too stuck in his old ways so he's gonna take longer but I love him so my subbornness will prevail one day. Nice one Del.

[@bruiser6479]

I really enjoyed watching your approach to mechanics in this video. I am of the opinion you were being perfectly reasonable in your views about contacting the dealer who sold you the bike. You were quite sensible in your expectations of what to expect. Where I live in Australia a problem like this would be a reasonable warranty claim on a second hand bike. Depending upon the purchase price of course.

[@Moonfleet41]

Yes indeed, it varies areound the world, but we did, indeed, pay full retail price for this bike and got the customary 3 months warranty from a reputable dealer... I didn't expect them to come and spoon feed me, but just throw us a bone and give us a clue how best to deal with it...which they did, we know have a firm plan and we'll get past it with no more drama!

[@bruiser6479]

Which just shows why showing loyalty and supporting a quality business is never a bad idea. I really like that you seem to be a very sensible and reasonable person. Keep it up mate.

[@mikeenglish7063]

Good luck with welding. I know its a headache you werent expecting. But this is an interesting project. Cheers for sharing it

[@Moonfleet41]

I feel the same mate, this was a little disappointment, but like you said, it makes it interesting and I think in the end, perhaps more rewarding to complete!

[@mikeenglish7063]

@@Moonfleet41 definitely more satisfying when finished, knowing how much youve done to it

[@myturkishlife1777]

Sometimes you can lightly tap in a torx drive bit into a stubborn hex head .. the 8points of the torx fit nicely into the edges of the hex head .. Lovin the series though ...

[@hdhardcore8511]

Such a shame. Really nice bike spoiled by lack off maintenance. Will this be a taking the head off or will you weld it? Keep fighting man, you'll win in the end. Excellent series - made me sign up to youtube just so I could comment

[@Moonfleet41]

Thank you most kindly Sir, it's great to hear from you, this is a poorly, neglected ol' bike, but am winning steadily! Take care and keep in touch, all the best, Del

[@MadNath]

@delboy I'm starting to get rust spots on my swing arm how do I get rid of this and touch it back up. I use acf50 and polish and wax my back all the time. So this shouldn't be happening.

[@d.fresh.750]

Big bummer there at the end, but good catch...before getting deeper in! Hope a good resolution can be had!

[@Moonfleet41]

Me too Sir, it's just a hurdle to cross, am sure we'll get through it!... it's a project after all, so no drama! Have a great weekend, ride safe, D&Px

[@clivewilliams1406]

Sorry to hear about the corrosion issue, I presume that the solution is 1) New head, 2) Weld and machine a new boss, 3) New (s/h) engine 4) Scrap the bike!? None of which will be any consolation, I hope you get it resolved. The Factory should be wholly to blame for this as it is totally predictable. If you do rebuild the bike I would consider replacing the mild steel rings with stainless ones that will need to be a good interference fit on the header pipe. The header pipes will ultimately rust but the strength of the stainless ring will be greater than the header and thus any rusting is likely to implode into the header. As regards your header bolts I have a few comments: 1) Using the ball end of the allen key is the weakest point on the tool. Ideally, a long hex key in a socket is the tool to use. 2) Rounding out the hex socket in the bolt was always a possibility (moreso if you use the ball end) but the solution if it fails is to use a torx bit that can be tapped into the socket, the torx points will dig into the corners of the hex and give greater purchase. 3) Whilst stainless bolts might be the first solution, the problem is that ss bolts are only 8.8+ grade whereas most socket headed bolts are 10.9 or better. Also, the bolt is under constant heating and cooling cycles and ss is weak in fatigue, thus will fail earlier than the mild steel bolts. I had this very conundrum on my HP aircooled Beetle engine, which I resolved by using 12.9 bolts, cutting the heads off and using them as studs. The nuts I used were copper coated K nuts with integral washers that have a 11mm head for the M8 stud, not the usual 13mm nut that is common with M8 studs/bolts. The K nuts are high grade steel with a deformed head that grips the stud to lock it on, also the nuts can take a higher torque than the bolts and or course, there is less of an issue with stripping the aluminium threads out of the head. M8 Copper coated K nuts are available on-line relatively cheaply as they are used for retaining the wheels on Go-Karts. I hope that helps?

[@Moonfleet41]

Thanks for all your input Clive.. i didn't user ball head keys at any point, only straight ones.. and they heads the wrung out simply crumbled dies to so much rust in them... got all but two out now, and ill have to drill and tap those this week... Thanks for your support buddy, take care. Del.

[@philiproberts6947]

I'm looking for a good work shop bike lift like yours for my own garage. Do you have any recommendations! Will make working on my Harley much more relaxing.

[@Moonfleet41]

Hi Philip, sure thing, it does make life easier and helps the back lol.... not sure where you are, but Sealey do a great selection, all different prices and sizes, depending on your garage set up, and I believe they can ship/drop ship all over the world... www.sealey.co.uk/category/5637150905/motorcycle-lifts-work-tables Hope that helps, enjoy shopping!

[@philiproberts6947]

@@Moonfleet41 cheers fella,much appreciated. Up in Liverpool so no issues for delivery. Been looking at Sealey and Draper lifts myself,just wondered what your personal preference is,as you use your a hell of a lot more than I will.

[@Moonfleet41]

@@philiproberts6947 Yeah, i had a light weight machine mart lift... bit flimsy.. so i opted to upgrade for the Sealey MT680A, beef enough to hold any bike i roll onto it and ill never wear it out... its built like a tank transporter...lol

[@JDnBeastlet]

I thought this would be great - a beautiful Saturday morning, a fresh cup of coffee and a new DBG video... but that exhaust port split is rough. Nevertheless, I am sure you will handle it with your usual style and aplomb. I echo the comment about ball head hex drivers. I used them for a little bit when I got into RC airplanes but quickly learned that straight hex makes far better contact and should be used instead of ball head whenever possible. In any case, another great video. As always, a learning experience. Great job, crew.

[@guy.h]

with the stuck allen bolts, as they are mild, could you MIG a nut onto them like you would do for a snapped bolt?

[@Moonfleet41]

Quite probably my friend, in the past I've MIG'd an allen key in to the hole, but knowing the threads won't be stuck, it'll be easier and less drama to just cut the heads off... !

[@guy.h]

@@Moonfleet41 true and you'll have the stub left if those ones are corroded in. BTW love the sparks on those 4 :)

[@rsbharley4766]

Sorry to see this Del, hope the dealer can help you out with the repair. As for the bolts, I have got a way with using a torx bit in rounded cap heads. Penny and you have a good weekend, hope your getting some sun. All we are getting is rain and more bloody rain, it's like being back there lol. Cheers

[@Moonfleet41]

Hi buddy, will swop you some of that rain lol... 27 degrees at the moment and blistering sunshine, but listen to us moaning ! We have a solution, the torx bit was a no go as the centre of the bolt just crumbled out and it's too small for the next size up!

[@docgreen4934]

Hi Dell - I’m just catching up on this “build” after a month. Noted the very many negative comments and all of them clearly don’t know or wish to understand the principle of negotiation and compromise!! More especially when the dealer is someone you know. Anyway, good man - we all get frustrated and the best way to overcome that is walk away and think before acting; something you clearly did. I suppose the mobile welder guy has now visited and so I look forward to the results from that. No doubt you’ll keep up the good work and as always, I wish you well. Yours aye, Alan

[@Moonfleet41]

Hi Alan, thank you my friend, yep, I think it's a lost cause trying to get through to some people, specially when they would far rather see the negative in everything... it seems the internet brings out the very worst in some people, but there you go! Lots of great footage, editing for Friday now!

[@Jrambo51]

Sorry to see the bad news. I hope you can sort something out with the seller. Takecare.

[@Cromwell648]

In future, use a two pronged attack to remove rusted in studs. 1/Heat. 2/impact driver. You will save yourself a load of grief!

[@chrisrag1346]

Damn. Not something you need really is it. Hope you get it sorted at not too much of an expense Del

[@Jeefster-is8xl]

Not the end of the world Del, just means you got to go a bit deeper than you planned. Sometimes these things happen for a reason. I think you need to invest in a decent rattle gun and some In-hex sockets. T-bars in that situation aren't the best choice. Good luck mate....

[@Moonfleet41]

Exactly Geoff, bit more fun and games than i planned, but its under control and we'll get past it... have a great Sunday buddy.

[@gunton21]

Bad news del, hopefully will result in a satisfactory outcome. Keep smiling. 👍

[@colineckersley7400]

Just found the same cracked ring on my gsxr750, Planning to use durafix aluminium rods. Goodluck to you.

[@nickmit4406]

My first thought was that. Don't use tig or anything like that. These rods will probably do wonders.

[@suzukietc1373]

I've tried those on a Suzuki gp100 barrel. Couldn't get it hot enough with a cheap blow torch

[@cunningplan96]

funny as you have just had a big mention by Shadetree about drilling out allen bolts. looks like your going to have to do it now!!

[@cunningplan96]

and forgot to say! Shame about the damage :(

[@Moonfleet41]

Cheers buddy, that was kind of him aye, and yup, business as usual with old bikes aye?!

[@christopherdevries1969]

Bummer... but such is life sometimes. Deal with it, Get over it, and have a cup of tea. 👍👍👍.

[@Moonfleet41]

Damn right Sir, tea cures everything !

[@benmorris7454]

Bummer , hope you get it sorted del

[@motorart4670]

Bad luck Del. If anybody can fix it, you can

[@Moonfleet41]

Thank you for your faith and support Sir.

[@terryblack2219]

I feel for you Del.... Let’s hope the shop take some responsibility and meet you half way at least... Thankfully these things are replaceable.. costly but replaceable. The other positive thing is people watching this will see things are not that simple when re-storing or building are not so simple.

[@Moonfleet41]

Hi Terry.. we've come to a plan, i really want to be involved in it if i can.. so got a mobile welder coming for a look Monday.. otherwise the dealer said he'd take it on and get it done, and id probably pay all outlay costs... we'll make it happen between us.. its wear and tear after all..!

[@scottthornton9237]

Del, I have spent 37 of my 60 years as a Aircraft Mechanic and at least a couple thousand hours working on motorcycles. I must say: Del you are the most Gifted Mechanic that i know of!

[@Moonfleet41]

Wow, thank you so much for such generous and kind words Scott, I perhaps would stop short at gifted, I'd like to think I'm determined and resourceful maybe, and I'e been lucky to have the support, and guidance, of some amazing people throughout my life. I had a great response from the shop, it wasn't on a 'claim' footing, just asked him for some help getting over it, and he offered to have his ali welding guy seal it up, and said it doesn't even need to come out the frame, to just drop over the bike in a van, but am gonna try doing it here at home, I've got a mobile welding guy coming along on Monday, gonna try and get over it myself... taking the path of least resistance, so trying to keep the costs down, sure we'll get there, it's a mini-adventure aye?! Thank you for your support Scott!

[@scottthornton9237]

@@Moonfleet41 I had a gut feeling that you were going to tackle this "in house" if at all possible! I am curious as to how you will "finish" the inside diameter of the exhaust port. This project has me on pins & needles awaiting the next video(s).

[@Moonfleet41]

@@scottthornton9237 Ha ha, thank you so much for your faith and support my friend.. !

[@ewwmin3m]

looks like the entire engine might have to come out to be able to take a goood look at that block, once you get the headers off and to be able to fix afterwards. It should be ok to fix as long as the fix seals the gasses. It's all about that proper gas flow

[@Moonfleet41]

Sure thing, gonna drop the exhaust off tomorrow and see how close the crack is to the ring seal and whether or not the ring seal has enough metal to hold it in place, if so, then it's just a cosmetic weld... fingers crossed, just another little hurdle!

[@Liam_Bollocks]

Can’t you get someone to tig weld the crack? Or is it sand casted ally?

[@Moonfleet41]

Chap coming on Monday for a look-see!

[@simonstillborn4951]

Bummer Delboy, good to see a man not throw his toys out the cott when faced with a catastrophic problem. It also reminds me of bikes and cars I've brought. I've never really dwelled on the km's but spent the time going over the condition of them. I learnt the hard way with a cuppĺa old Datsuns.

[@Moonfleet41]

Sure thing buddy, I've never felt emotions like anger when it comes to engine problems, just doesn't' dawn on me to feel that way... disappointment maybe, but then it's a new adventure to embark on and something to challenge myself with... every day's a school day aye?!

[@RABLACKKNIGHTS]

Dude you will fix that easy. You the man

[@russellfay2855]

Hi Del, I think I would call it a day on this one, the problems are becoming deeper and deeper and you may end up spending more than the bike is worth. Get the street fighter back on the bench for the seat pad to be put on and prep for the wrapping that you said was gonna happen. All the best Del and Penny.

[@Moonfleet41]

Hi buddy, nah, never give up, am in to it now, and the fighter is already with the wrap company, they are wrapping it first, then the seat pad will go on top once it's back (bit it will all be covered on video to form a conclusion to that mega long project!)...

[@gintautasnik5214]

Sorry about this situation. I'm glad you changed your intro track style tho

[@patsonabike]

I feel for you. Corrosion like that would be my biggest fear considering the meagre amount of proper tools I have and the lack of an indoors to work in. I would be crying if I had found that crack. I'm glad you are finding an amicable way forward with the dealer. I have to travel about 45 miles to get to a dealership where I can 100% trust in what they are doing. They also do a really great coffee morning once a month. :) Anyway, I just literally had to take out my exhaust system in order to work on the rear suspension linkage. I don't even have the option of replacing the bolts because they seem to be part of the engine block, just threads sticking out. I am so aware of that that I slather anti-corrosion stuff on regularly and am always careful to keep that area clean. I suppose taking the pipes off once in a while is also a good way to check. Looks like this has never ben done on your Bussa. What a shame. Negligence always has unnecessary price tags attached to it. Try and have a good weekend anyway. Stay cool, just for a change. :)

[@Moonfleet41]

Hi Patricia, thank you, it's not as much of a drama as it looks, it's a project bike after all, and bought it knowing it was a big neglected (but not quite this much lol)... we'll get there, and learn from the process! Have a great weekend, at least the sun is shining! Ride safe, D&Px

[@jllindle]

If you strike the head of a steal bolt that goes into aluminum it will take some tension off. Makes it less likely to break or strip out. Bike is looking good.

[@americanotakuinc.9637]

It’s a good thing you caught that. That coulda been very catastrophic later on down the road if you hadn’t. Hope you’re planning on replacing the hoses next to the collars as well. They look like the grave. Oh side note, your goodies are sent off already. I’m gonna order the last bit tomorrow. Your gonna be over the moon or just really chuffed at what I’m sending you. Have fun testing them or using them. Lord knows you need em.

[@Moonfleet41]

Thanks buddy, good to hear from you, and we'll keep an eye open for the parcel, will let you know when arrives, really appreciate that! And yeah, onwards and upwards... we'll get it sorted! Have a great weekend, and enjoy the sunshine, D&Px

[@spo5egy]

That's a bummer but completely fixable with aluminium rods and a blow torch. Gently cut a v into area and part round ends with a drill bit. Get it sterile clean. Also for Allen heads... Drill slightly in and get a reverse thread stud removing set for around £10 it's a great investment. Best of luck. Btw you sound like a non swearing Gordon Ramsay 😊 but a better version 🤣 all the best.

[@hartley383]

Thats a blow Del, hope you manage to sort something out. On the siezed bolts, similar to what ive seen you do when tapping an allen key when loosening bolts on those id also try getting a drift and hitting them on the side of the head whilst undoing,(usually need some one to help) not to hard obviuosly but the shock would certainly help free them off.

[@nlpx]

"turned them down to eleven".... usually you would turn it up to eleven ;)

[@KainamHD]

Ive had a cracked cast aluminum starter mounting boss for a Harley TIG welded which subsequently lasted 30 some years and counting.

[@bill_4359]

I watched a tv show where a Loctite engineer demonstrated his product that repaired a crack in an engine block. However that was a steel block on a V8 racing engine.

[@Moonfleet41]

It's good stuff for sure.

[@garya3056]

That’s heartbreaking, Del. Hope there’s a workable resolution. Your lathe work is amazing btw- truly is, Mate! 🏍👍🏍

[@Moonfleet41]

Hi Gary, thank you for your kind words, as ever, yeah what a disappointment aye... was so hoping to just crack, and replace, 8 bolts and slap the radiators back on, but ho hum, that's life! Have a great weekend... ride safe!

[@garya3056]

Moonfleet41 if anyone can win this battle, it’s you...

[@Moonfleet41]

@@garya3056 Thank you Gary, Your faith is comforting..

[@istvanvigh2367]

Serious challenge! Corrosion has caused serious trouble. I'm curious about developments.

[@3475883]

I'm with you on calling the dealer. That spot on the head needs to be welded back in place, and the question is who does it, does the head have to come off...etc? On a lighter note, please ask Penny to at least make a cameo on your vids from time to time. Let's us know her body isn't stored in a freezer somewhere! I have been a sub for a long time and miss seeing her.

[@Moonfleet41]

Hi buddy, thanks so much for your kind faith and support... Penny is fine, she says 'Hi', but sometime ago she made a decision to step back from the videos following the vile filth, and abuse, we started to get aimed at her orchestrated and incited by two particular individuals, and until we deal with that side of it, I'm not exposing my wife to any more abuse online... she's a busy professional person and has her own company to run and she needs to stay positive and focused... it's a real shame, I miss her being in the garage too, but that is the price that the good people, sadly, have to pay for the vile destructive filth that comes from the bad people online. She says 'Thank You and Hi' and says she really appreciates your very kind words and support.

[@iGMAS]

I wouldn't put stainless bolts in aluminium threads. Get Depo / Metal flake bolts if you want more corrosion resistance. The stainless will corrode the aluminium.

[@Spad562]

Yeah I tend to agree with that too

[@scottthornton9237]

I have to disagree, I machine Stainless steel bushings to repair worn aluminum on aircraft, for a living. Any and all metal will corrode. Its the nature of the beast. All Dissimilar metals will corrode. Corrosion has three components 1. The Anode, Aluminum in this case. The Cathode, being the steel or stainless steel fastener. 3rd being a conductive electric path, usually water. One of the components must be removed from the equation. The easy one water! Using a thread sealer like Copper Coat or any number of good assembly fluids work well for this. Just look how many mechanics swear by Lock-Tite.

[@Moonfleet41]

Thanks for that great input, that kind of reassurance from the professionals gives great confidence.. cheers Scott.

[@iGMAS]

@@scottthornton9237 Would use a non metallic anti seize to stop the reaction. Also I meet these mechanics every week (I delivery fasteners to industry) and always recommend when they want to put stainless in aluminium and iron threaded hole that they take what OEM put there which is nowdays Depo/metal flake zinc or zinc+nickel. Before that just galvanized zinc bolts. Also that bushing you use is so small compared to the aluminium frame of the plane that if it was reversed the aluminium bushing would corrode away in no time. But everything that has to do with rust and corrosion is all about how long do you want things to last.

[@scottthornton9237]

@@iGMAS Do it however you see fit. To quote you sir "take what OEM put there ". I will take my 20 years as a Factory Trained Mechanic ( Douglas Aircraft & Boeing combined) and add to that an additional 17 years as a Naval Aircraft Mechanic and Machinist experiences. I was the OEM for 20 years. just sayin'.

[@DeluxeChimp]

And here I thought getting the exhaust off of my old EVO Heritage with severely rusted nuts and studs was nerve wracking.

[@martincarey8620]

That heart wrenching, sickening feeling. Oh my. No simple fix for this one, so really hope you can sort something Del

[@Moonfleet41]

Hi Martin, good to hear from you buddy... hope life is good.

[@anthonyprice5596]

Only one way to fix that properly, remove the head, get it welded and machined to the correct diameter. Maybe while your at it, grind off the front pipe rings and replace them with 316 stainless rings, that way it won't happen again.

[@RenchRanch]

Welp, that sucks! A good welder with the proper rig can do that up right. I've seen it done many times on things far worse. Should be good as long as the surface inside the flange port is also totally corroded and won't make a good seal. Good luck! Swapping a head would be a major pain in the arse! Mike & Melly

[@Moonfleet41]

Sure thing Mike, I think it's more than rescuable, I've got a mobile welding guy coming on Monday for a look, fingers crossed, hope you're both well, catch you soon, hugs to you both, D&Pxx

[@fuelheadjay8800]

By freezing the bolt shrinks it so spraying the metal tool would do the same so it would be lose in bolt.

[@leminako]

That's real bad luck😖. But nobody could now this until you work in that area. Hope you can get an acceptable arrangement and continue the build. Good luck Best regards Dieter

[@Moonfleet41]

Sure thing buddy, he's a great guy, he's offered a great suggestion and gonna try it myself first, by using a mobile guy, otherwise will run it over to him.

[@baccas66]

Feel for you bud. Will wait for the follow up. Many dealers will sell you a bike, but very few it would appear, offer back up and assistance when required by the purchaser. A good dealer relationship is essential, and worth holding onto.

[@Moonfleet41]

Thanks buddy, its under control now, ive known these guys long enough to know they'd offer to help.. and they have.. we've got a plan, and it's gonna be all part of the journey... take care buddy, and thanks for your support.

[@MotoMirius]

Header bolts in Damage are just the same and it’s a job I’ve been putting off. At least one of the header clamps is rusted through which will be interesting. Head needs to come off as well. Hopefully there won’t be too many other surprises!

[@bigogger50]

You could try the impact screwdriver to remove the remainder of the bolts. Not sure about the busa but there used to be a crush seal against the cylinder port face even with the guide sleeve damaged you should still get a seal

[@neebob2]

Seems like a job for an electric impact driver . It's been my go to tool for years of bike disassembly . The small 1 construction workers use .

[@noelshed689]

Been there cool work 💕💕💕👍👍👍

[@djangoholic]

Induction heaters are great for rusty bolts

[@davidlisi1047]

I had to get some irwin extractors on my head bolts when I had the same issue with the allen key just spun, they work a treat, needless to say they're stainless now

[@Moonfleet41]

Sure thing buddy, just gonna drill these off as am a bit up to budget on tools at the moment, they should come out ok, the threads aren't jammed, just the rusted heads stuck to the plates!

[@davidlisi1047]

@@Moonfleet41 you ever heard of eds red? It's a bore cleaner for guns but it makes for a very good penetrating oil and it's home made, works very well on stuff like that, because its what I used =)

[@davidbray9849]

I think it's about time you invested in some MAP gas it's great, gets the bolts cherry red in no time

[@suzukietc1373]

Always a bit of second hand cringing when watching someone remove header bolts, we've all been there when they give way Haha. I've replaced mine in the past with stainless bolts, makes such a difference even on my bike that I've been through multiple winters and never washed lol

[@jamesgoodwin2450]

Looks like a tig welder is needed,either that or another head

[@Moonfleet41]

Gonna strip out the pipes and clean it up a bit to see how bad it really is, a buddy of mine is a pro mobile welder, he's coming to see it on Monday!

[@ciaranmckeown4536]

If worse comes to worse a new head can't be a massive set back to a fella like you , just an excuse for another great video

[@johnrode7109]

Easy fix pull the head and put a good use one on or just weld that one up and clean it up

[@Moonfleet41]

I think weld it up is the first option, wish us luck!

[@allenhumphreys2586]

I would just R/R the head, but IAC I would remove head(or the complete engine !!)and check overall condition, there's a lot of corrosion in that engine area, there could be more hidden damage, could probably pick a up a better condition used engine !!. No fault hidden damage on a used vehicle is usually a toss of the dice, good luck. A good engine teardown/inspection video is always cool 😎

[@martin319]

Blimey never seen that before, hope you can sort it dell.

[@Moonfleet41]

Me too mate, and pretty sure I can!

[@anidiotinaracingcar4874]

6:48: new way to lit a fire I've seen in absolutely no survivalist show

[@jimwilson2287]

Use a dab of valve grinding compound on the tip of your tool. It will give you extra grip on the worn/corroded bolt heads.

[@Moonfleet41]

Good tip, thanks buddy.

[@robertmillington50]

Gutted bet that's put a dampener on things hopefully you will be able to sort it out

[@Moonfleet41]

Naah, not at all mate, its a mini adventure. .lol.. ill get past it.. its a Rat bike build.. as long as i can make it serviceable, it doesn't matter what it looks like. Just a rainy day moment aye..lol!

[@johnmccallum8487]

Might be an idea to NDT the whole bike frame as not all cracks and defects are visible to the human eye, just a thought,

[@damienrichardson2524]

Would ACF 50 be worth spraying there every year del ? Might keep the rust away after along wet winter ?

[@Moonfleet41]

No chance mate, it would vaporise in a moment right on the exhaust port, no spray on protectant is that heat resistant.

[@REKLESSWOLVES1]

Wow, gutted for you mate, shit happens especially on old bikes and like you said really no one`s to blame, as such, it`s just inaccessible areas like that that are prone to corrosion, who knew,, anyway instead of blowing a gasket ( ;) see what i did there lol ) and kicking off at the bloke who sold it you, you politely informed him of the issue and Top bloke fair play to him he`s offered up a solution and helped, some knuckle dragging garage owners wouldn`t and would say `tough shit mate you bought it as seen`, all in all a decent result in the end, okay it`ll take a bit longer to get the Busa finished but on the bright side it`ll be safe and that`s the most important thing here,,, ohh and it means we get to see a few more Busa Build Videos now lol, have a safe weekend to you mate and all your biking viewers out there. Peace.

[@Moonfleet41]

Thanks Glen, yes mate, we have a plan, and its under control for now.. really appreciate your support buddy.. have a great Sunday.

[@user-ov3vf3lj8l]

What a day

[@steveman1982]

First time ever I'm seeing sparks come off when loosening bolts!

[@Moonfleet41]

Me too I think mate, perhaps it was the penetrating oil !

[@shaunoneill4253]

Low temp alloy brazing rond !!not cheap try them bloody amazing

[@Moonfleet41]

Yeah, have heard good things about them, it may be an option ... thanks!

[@gilesbristow123]

Dealer sounds like a really good stand up sort of guy. I'm sure you'll fix it and it'll be really interesting for us to see it being done.

[@Moonfleet41]

Damn right he is, as you saw, he already replaced my fork stanchions free, and all this is wear and tear, so he's not really obliged to, it's a 20yr old bike that's lived in the weather, he's already offered me a solution on this, but gonna try and get round it myself, fingers crossed!

[@551moley]

That looks to me like a new gasket will seal it, the crack isn't on the mating face, not Ideal but needs must!! "Tint" like it's a proper bike! the tyres aren't knobbley enough..

[@merquisonmototardivo5806]

Nossa que trabalho está dando está Hayabusa até parece que estava enterrada heheheheh

[@georgiosphilos2146]

I believe this can be welded and be enforced with additional material.Man I haven't ever seen such a corrosion on a bike...

[@Moonfleet41]

Yeah, me neither Georgious, it worse than any bike ive owned.. but not insurmountable.. i think you're right, it can hopefully be TIG welded and beefed up... gonna strip the exhaust out tomorrow, and clean up the area... then i have a welder coming Monday to see if its feasible..

[@HalfdeadRider]

@@Moonfleet41 I hope it can be or it's a search for a decent head or another engine. A new (used) head would be cool, if you could afford it a rebuild and restoration of the engine internals would be right up my street, new bearings, seals and rings, done all that many moons ago on an old XR3i with worn rings, easy peasy on those old CVH engines :)

[@Bimmer_e90]

Nasty hidden secret...pity Del.