Motorcycle case repair, welding, RM250, F7

[@jamesws3]

Fascinating repair. Amazed at what you did here. Very creative, especially the manual trimming. Two more saved. Well done!!

[@montana2strokeracer]

Thanks Jim, it's all fun, anything one of these needs it's a new great challenge. I'm game.

[@johnfry9010]

Beautiful repair Dale !

[@montana2strokeracer]

Thanks John, I am not the best welder, but I get the job done.

[@ianbarnes8593]

Very nice repair, Dale. Care and patience always pays off! You always seem to catch the locomotive horns blaring in the distance whenever you’re outside of the shop.

[@montana2strokeracer]

Thanks Ian, yes the train yard is about a half mile from me. I guess I just get use to them. Thanks for stopping by!

[@petermckee1061]

What a great job! Amazing repair. Cheers, Peter.

[@montana2strokeracer]

Thanks Peter, great to see you here as always.

[@LordLucan-7]

Just discovered your channel. It's truly fascinating watching you work and strangely relaxing. Subscribed👍

[@montana2strokeracer]

Thank you so much for watching and subscribing, hope you will continue to spend time with me in the shop!

[@kepamurray1845]

Awesome, thanks Dale. I do quite a few of these types of repairs for our club members bikes. I've been meaning to do a video but balked at videoing the welding. I will be pointing them here to see the process. I normally preheat the cases. Just works for me.

[@montana2strokeracer]

Thank you, nice to hear you are taking care of the club members. These cases are just very vulnerable out on the trail. I just use my old welding helmet lens taped to the camera. Works pretty well. Yes, I preheat also, but I do it with the TIG torch, I just run around the weld area, that also brings up any impurities as the temp is brought up at the same time. The cleaning action of the welder cleans it up pretty good in most cases. Sometimes you need a stainless brush on the bad stuff.

[@retromechanicalengineer]

Lovely job Dale. Pleasure to watch you work. Best wishes, Dean.

[@montana2strokeracer]

Thanks Dean, you're getting close to that 1000 mark. Good job!

[@retromechanicalengineer]

@@montana2strokeracer thanks Dale. More to come. Time has been working against me!

[@montana2strokeracer]

Understand my friend, have been in the same many times. It will come around at some point.

[@flipfix]

Nice work Dale, I learned a bunch. Going to order a tap follower/guide now that I know they exist. Straight tap jobs here I come!

[@montana2strokeracer]

Good job John, the tap follower really keeps you straight. You will enjoy it.

[@markaddy53]

great repair dale should last a lifetime keep up the good work next video please

[@montana2strokeracer]

Thanks Mark, at least till the chain comes off again.....LOL

[@debbiewillis1302]

Looks like some more snow Dale , thanks for taking us along on the ride, 👍🏻 watching from down under Australia

[@montana2strokeracer]

Hey Barry/Debbie, yep, no shortage so far this year, think we are catching up from last year's shortage. LOL

[@gigicocreates]

Hey Dale! That was fun to watch. You are so talented and resourceful. Grateful for all that you do. Appreciate you sharing all this with us. Thanks Mate!

[@montana2strokeracer]

Hey Gigi, haven't heard from you in a while, you been on holiday? Glad to have you here having fun with the rest of us. How is the AS1 coming along?

[@gigicocreates]

Hey@@montana2strokeracer, glad to be here again. Actually, I've been having issues with my Health and we've traced it back to bad guttering and black mold. It's been unusually wet here for the past year. Long story short, they finally cleaned it up on the inside of the house, and my health has improved, but now I need to move because I know it will only come back again if they don't fix the roof and guttering. The AS1's tank is de-rusted with transmission oil in it, I have found all the cosmetic pieces for it. Built a couple bike stands, (the second one for the Suzuki 79 TF185). Was about to work on the wheels when all this went down. Now, I'm packing and getting things organized so I can hit the ground running when I move to my new place. As long as I keep watching your videos, I will keep the fire stoked for working on the bikes. So thanks again for all you do!

[@montana2strokeracer]

Hey Gigi, man that is terrible, that stuff is a cause of a lot of folk's health problems and some never know it. Glad you have a handle on it and are recovering. Think you are doing the right thing to move. Hope you are on the way to stellar health. Sounds like you have had some success with your bikes, at least by finding some of the parts needed. So, you also have a TF185, I am not familiar with that one, is it like the TS185 imported here I wonder. Hoping for full recovery and a quick uneventful move for you. Thanks for spending time with me in the shop!

[@gigicocreates]

Thanks@@montana2strokeracer, I am doing much better yes. More energy, got my strength back. Muscle spasms and stiffness not as bad now. I'm a very physically active and productive person, so it was a real bummer at the time. I beat Cervical Cancer, so I am very confident I can beat this too! I have always loved Motorcycles (used to have a Honda 750 Shadow as a daily driver) , so this is my happy place :). The TF185 is indeed almost the exact same bike as the TS. The F stands for Farm. It was geared lower for more torque. There are plenty of TS's here too, so parts are fairly easy to find for that one. The tricky part was finding a Carb. I found a FB Group for Suzuki TS and TF's and lucked out. Got my carby and some electrics for it too. I get wait to get this move over with so I can get to work on them.

[@montana2strokeracer]

Glad to hear you're on the mend, it's just hard to do hobbies, anything for that matter, when you don't feel good. I understand fully. I know the feeling about the happy place, when I'm not making videos, I watch everyone else's. This is just what I like to do. I had seen others talk about the TF series bikes, but really didn't know what they were about. Now I know. Good luck with your move and getting your work area set back up so the motorcycle fun stuff can continue. Glad you're feeling better.

[@vettepicking]

Nice job. Machinist tip for threaded hole location. Put a screw in the lathe jaws and turn the head round and tru, thread into hole and indicate screw head , zero dro and now you are centered over the hole. Now you have a locating screw for next time

[@montana2strokeracer]

Thats why I like you Matt, you are a smart cookie. I'm writing all this stuff down you know. One day I might also be a smart cookie.

[@vettepicking]

@montana2strokeracer lol. Ill come up some day

[@kerryyeroyan8212]

Nice work Dale!

[@montana2strokeracer]

Thanks Kerry, I sure appreciate you stopping by.

[@kerryyeroyan8212]

@@montana2strokeracer Certainly planning on it. Been so busy lately and with the weather change it’s got me working in the office much more.

[@cainbeeping8480]

Great job on the repair.

[@montana2strokeracer]

Thanks Cain, got it done.

[@donbridgewater2988]

Awesome job Dale, better than new!!!!

[@montana2strokeracer]

Thanks Don

[@garyisabelle8078]

Yes! I see your center drill is getting some action today.

[@montana2strokeracer]

Thanks Gary, I knew you would be impressed.

[@muggins57]

Quality mechanical work and good video production! Thanks for sharing!

[@montana2strokeracer]

Thanks Styles, I am trying some new things to make the videos better.

[@davidleland8729]

Nice repair work Dale!

[@montana2strokeracer]

Thanks Dave, still making progress on your bikes?

[@davidleland8729]

@@montana2strokeracer The 71 TM250 and TM400 are done. I will be riding them this weekend to see the results of the upgrades.

[@montana2strokeracer]

Awesome Dave. Have a good ride my friend.

[@davidleland8729]

Spec changes are 1" increase in wheelbase and 2.5" increase in ground clearance.

[@davidleland8729]

Good evening Dale. Had a great day on the bikes. I went to the area where I used to ride back in the day. Was glad to see that it hasn't been developed yet. The results of the upgrades did not disappoint me in the least. Throttle control and acceleration were on point and the handling was greatly improved. And I want to thank you for the friend reference. I haven't been called that in a very long time.

[@Corey-dy2cq]

I need to take a welding class. In high school all we had was stick and oxy acetylene. Now you can do so much more.

[@montana2strokeracer]

Hey Corey, I know what you mean, I was raised on a farm and had a lot of experience with stick and oxy acetylene. But in those days if you needed aluminum welded you went to some dark corner of town where you heard there was a guy with a Heli arc machine that could do it. Several years ago, I decided to see what all the hype was about around the now term TIG, well the worst part is the price of the machines, but these days you can have a nice one for less than a thousand, and they will weld everything. Lots of fun, highly recommend expanding your skills. I am not what I would call a good welder, but it's fun trying and sometimes I surprise myself. Now that's fun!!

[@jeffsilver4730]

Epic video! You're pegging the talent meter again Dale. Thanks for sharing your means and methods, I've learned a whole bunch from your videos.

[@montana2strokeracer]

Thank for the kind words Jeff, just enjoy doing this stuff.

[@montana2strokeracer]

Thank for the kind words Jeff, just enjoy doing this stuff.

[@frankdillon6127]

Just think 50 years from now someone will open up that engine and say look it was repaired once. Dale you should sign and date the repair for fun.

[@montana2strokeracer]

Oh well, don't think I will care in 50 years.

[@frankdillon6127]

for sure, just thought if i opened up a case and saw a note from the previous mechanic with a date it would be cool.@@montana2strokeracer

[@johnreid2837]

Very nice work.

[@montana2strokeracer]

Thank you John!

[@customgaragemoto7590]

Top 👍👍👍👍👍👍👍👍👍👍👌

[@vinnyvinson]

👀 this is amazing salvage tech. Cool to see the possibilities. I usually give up projects that have engine damage like this. Now i will have to consider taking them to a machine shop. I really hate parting stuff out.

[@montana2strokeracer]

Thanks Vinny, just start off slow, pick up a welder and try it yourself. You could do this with a drill press and a grinder if you had the welder. Just something to think about. I know and agree.....hate parting out bikes. Hey man the days are getting longer here in Montana, as I am sure they are in Alaska. I am ready to unthaw.

[@johnnysgarageTX]

Thanks Dale. Nice work as usual.

[@montana2strokeracer]

Thanks Johnny, sure appreciate you spending time here in the shop.

[@steelcityperformancesaws]

beautiful truck

[@frankdillon6127]

4:31am Thursday, but I'm here!

[@DarrenNoonan-to8ut]

What a great job love your work

[@montana2strokeracer]

Thank you, Darren, glad you stopped by the channel

[@ntnsty]

Impressive!

[@markfranks48]

Good job new subscriber

[@montana2strokeracer]

Thanks Mark, and thanks for the sub.

[@cozydram1]

Hi Dale ..........that is awesome not only you have a filter for the camera but you can see the arc on the Tig, also it's way better / cleaner than the Mig, and no splatter ...neat, it seems your not using argon gas is that right??? using a stainless steel dowel would that be a issue with dissimilar metals attacking each other??? thanks for taking the time for us to see the process.........and yes I'm a newbie to this welding stuff and it fascinates me even at 65 yrs. I have recently started playing with Mig welding and boy the splatter clean up sucks........cheers Phil

[@montana2strokeracer]

Thank you, I am using my old welding helmet lens taped on to the camera. Yes, I use straight Argon for TIG. Should not be an issue using stainless on aluminum, the factory used steel pins in the aluminum, and it rust terribly. This should be a step up. Yes, MIG does have some splatter but not terrible at least if using Argon CO2 mix. If you are using flux core, there is a lot of splatter. If you are using Argon CO2 mix and still have bad splatter check your polarity. Thanks for spending time with me in the shop.

[@cozydram1]

I think I will upgrade my welding equip to big and argon next I just liker the fish and control better thank you for replying chap. regards. Phil

[@georgedreisch2662]

Not to knock your technique/ method. In the past, I’ve used bushings secured in the t-slots of the mill table, to establish datum’s, then recorded the relevant bore / hole locations from the DRO, done the welding, put it back on the mill, and machined the holes. Saves making fixtures each time. Eventually ended up making stepped bushings that fit in the holes on 1,2,3 blocks, to clamp down on the mill table and provide more flexibility of location and stand-off from the table. Have found it works well for timing etc..

[@montana2strokeracer]

Hey George, no offence taken my friend. If I was a machinist, I would probably understand all of that stuff about datums and such, but being the farmer I am, it would have taken me longer to think about that process than to do what I did. It was just a couple of one-off items repaired, probably will never do another one like them. I just am not checked out on the DRO's, the main reason to get a DRO in the first place was my worn-out Bridgeport, just so I could tell where I was and was going. They make a worn-out machine more friendly for an amateur. My channel is more geared to motorcycles, I have tried to incorporate some of the machine shop stuff that is related to them in my videos. I remember before I did my own machine work, all I knew was I dropped off the part at the machine shop and picked it up later all nice and done. Not knowing what went on between drop off and pick up. Just know others had the same thought and might be interested to know what was happing to their part during that time. Although my procedures might be archaic, they do get the job done. Not like a real machinist but done just the same. Thanks for spending time with me in the shop.

[@mrutherford8590]

On the pointy screw put two flat spots on it so you can take it in and out with a small wrench.

[@666goats]

Ditto, tremendous idea.

[@montana2strokeracer]

Good suggestion my friend. I will do it next time, the pliers way is a mess.

[@RW-kd4gx]

Cool

[@MiklaDfar]

Nice job. But why not use the DRO on your mill to find the centers while holding the case with a simple jig and then reusing that jig to drill/tap the hole.

[@montana2strokeracer]

Thanks Mike, if I were a real machinist, I would probably know how to do all that, but you will have to excuse my farmer approach to these repairs, it would have taken longer for me to think about all that, than to get it done this way. I am trying to learn more about the DRO but the old saying keeps knocking at the door. "Can't teach an old dog new tricks."

[@dralexmclean]

Very slick Dale: My F7 has exactly the same issue where the dowel goes and again from a broken chain apparently. You've emboldened me to try fixing my case. So a question or two, did you basically do both repairs on that F7 essentially non-stop or did you do some, stop let things cool down, then go at it again. I did not hear you comment on watching for oil or other debris to boil out of the casting before you added rod. Did I miss that or was there in fact really not significant contamination once you'd done the grinding and acetone. Amperage - looks to me like pretty light current flow taking your time. I did by the way talk to a machinist friend who will sleeve the shaft on my F7 crank where corrosion had ruined the left hand seal surface so belay my earlier question about an F7 crank. Thanks again so much for taking the time to make these videos, they are incredibly well done and detailed. Alex

[@montana2strokeracer]

Hey Alex, that's great, I wish you success with your project. No, I did all the welding on both engines then cooled slowly, then did the machine work and shaping. I didn't run into hardly any contamination on these two engines. Pretty straight forward welding procedure. Clean, grind, clean again, preheat with the tig torch and then weld. I like 5356 rod for cast aluminum cases. There may be something better, but it works good for me. If I remember I was running around 85 amps most of the time, topping out at 100 amps. I guess I didn't see the question on the crank, some drop through the crack for some reason. But that is good that you have someone that will be able to save your crank. That is a very straight forward repair and will make it better than new with the stainless sleeve. Some folks use speedi sleeves, I just don't like them for that particular repair, much prefer the thick sleeve I make and can massage down to a perfect fit with sandpaper and crocus cloth. Great to hear your making progress, let me know how everything turns out.

[@dralexmclean]

Thanks Dale: I have 4043 but I'll pick up a lb of 5356 to try for this (won't be the last case for sure). I assume you have DRO on the mill and wondered why you don't use that to align the holes and case position. I'm going to play with using the DRO to align and map my holes for the case machining. Your approach seems to require more skill and I'm nervous. Again, thanks SO MUCH for posting all this stuff, VERY inspiring AND very informative. Alex@@montana2strokeracer

[@montana2strokeracer]

Yes, the 4043 is best for 6061 aluminum, like new plate or tubing, 5356 works better for cast aluminum. I had others ask me about the DRO, I am a rookie at anything computer, or stuff like that, it would have taken me longer to think about how to use that, than to do what I did. Making a template only took about 15 min. If you're a computer guy you will make easy work using the DRO for sure.

[@dralexmclean]

Dale - you make me laugh. I can't magine the knowledge it takes to produce your videos. Different tech I guess.@@montana2strokeracer

[@mikemaifeld6280]

350cc 1970's Bighorn or 250cc Bultaco both in poor condition, in your opinion which would you pick to make run. Access to parts .

[@montana2strokeracer]

Oh boy, that's a tall order Mike. Both are harder to find parts for than say Yamaha or Suzuki. I have a 70 F5 Bighorn, and it has been a challenge to find parts for, it will be coming back to the shop in the future. I also have a 74 Bultaco 350 Alpina, and it's in the same boat. But on the positive note.... parts are out there and whichever one you decide on, they can be found. Good luck with your project.

[@cainbeeping8480]

First