Topic: CB400 Four, version 9.0 for ME I flip for 400 fours

[MoMo]

Not to be cynical but, I see no practical way to weld that case back up. The thickness of the alloy in those areas will make it extremely difficult to weld without distortion. The face of the piece missing (where it meets the stator cover) would likely need to be machined to be dead flush, or you could have misalignment. To weld that up properly, you'd certainly need to split the cases, super clean the cases, then weld. If you're going to that much trouble, replacement cases are a far better option.

Were the cases a super rare Sandcast, I'd say sure, try to fix them. But you'll need an extremely talented welder to make a proper replacement and then some machining behind it to blend it in where it doesn't look like road rash on a supermodel. You might ring up Jim French to get his thoughts?

I had a carb fixed by Jim- and was thinking I'd send him a couple photos to get his feedback Cal...Larry

[strynboen]

you can easy weld that engine casting ..most alu boats are 1-2 mm thin/thik..and veldet in full length..just find the right velder..

[MoMo]

Case isn't special, just that I don't feel like swapping cases.  I am headed to an aluminum fabricator tomorrow. Worst case scenario I have to swap cases, best he's able to do some sort of repair.  Theoretically, I could run the bike as is with duct tape covering the gap to prevent water from entering   ....Larry

[MoMo]

Flipped the bike upside down again to reinstall the center stand.  I've always used the same #3 phillips I've used for 40+ years to install the spring.




Bike on the lift and front end removed,  hard crusted dirt/grease but the races and balls look decent after cleaning.  Not sure if I'm going to go tapered or use a spare set I have. Bronze swing arm bushings ordered(that'll be the first money I've spent other than purchase price.

[MoMo]

Thinking of heading in a different direction. 

Maybe cut off all the tabs and install a rear hump(it'll be hump day everyday ).  Then fabricate a really hard plywood seat with minimal foam(I'm getting a bit soft in my old age so I figure a real hard seat will help tighten up my butt).  Next will be the installation of clubman bars(again, since I'm getting older I think leaning over real far will help to loosen my creaky back).  But.................."if you can't drive with a broken back at least you can polish the fenders".

It goes without saying that I'll most likely have to smash indentations into the front of the tank so the clubman relaxation bars will clear.  Since I'll be indenting the front of the tank I might as well add knee indentations.  Might even find some rubber pads like the old Honda 350's had .


The front fender will have to go,  all the road grime splashing into my face will make me look real tough.


I'll need to add a Sparta Limp Dick taillight(fitting for a man close to 70).

Finally, since I don't have much to do with the rest of my life, I'm going to add PODS, a header and open exhaust.  Trying to tune the carbs properly should occupy most of the time I have left on God's Green Acres.

After all that work is done I should be the coolest guy in Gap and King of the local Starbucks


WHAT DO YOU THINK?

[Stev-o]

DO IT!

[MoMo]

DO IT!

Glad you concur ,  if Granny(the little old lady from Pasadena) was still here I know she'd go along

[grcamna2]

DO IT!

DON'T DO IT !! 

[MoMo]

DO IT!

DON'T DO IT !! 

White Lines  -    Grandmaster Flash and the Furious Five

[zammykoo]

Don't forget to have your name written in script on the tank - maybe even throw in a lightning bolt or two!


Sent from my iPhone using Tapatalk

[strynboen]

you can easy weld that engine casting ..most alu boats are 1-2 mm thin/thik..and veldet in full length..just find the right velder..

you can easy weld that engine casting ..most alu boats are 1-2 mm thin/thik..and veldet in full length..just find the right velder..

Welding a raw, new piece of aluminum is a far, far cry from welding a cast piece of alloy of unknown spec that is 40 years old, filled with impurities like oil and grease, and has a machined surface on a radius with a jagged edge. MIG welding with a wire feed gun a sheet of pristine aluminum on a jig fixture is something I can train a monkey to do in about 15'. Apples and Elephants Stryn, Apples and Elephants.

It can be done. I would not undertake it in that area because the welding is only 1/2 of the repair.

See what advice Jim has. I suspect his recommendation will be to swap cases (unless this case is so vey special to you).

yes.. not all cast alu can be veldet..some types hold sand..dirt air nothing..and other non velding materials..mixed in the casting
i have working at vestas/nordtank/Siemens windmill fac in denmark for 10 years..so have some ideas of welding..and ve have done a lot of mc engine reparations..so this is a easy job(. easyer then speak English...).and gives Space for somefilling/ bakking at the inside. to give a nice surface grinding at the autside.at it not kritic komponents at the inside..you can use keramic to back up,at the inside..and some gas back.. flov vill make it nice looking..a glass blast vill dry all oil aut..and a after heat vith a gas burner vil sveat it aut,if  some oil have get stuck inside the material..so a ekstra blast vill klean all up

[MoMo]

Dropped the motor off, owner says no problem, as strynboen says it is not in a critical area so I'm quite confident it'll work...Larry

[grcamna2]

Dropped the motor off, owner says no problem, as strynboen says it is not in a critical area so I'm quite confident it'll work...Larry

Will he put a fresh piece of cast aluminum into it ?

[MoMo]

I happened to find this in my stash of spares. Also had new fork seals laying around so they were installed this morning before having to leave for work.  Tire decision forthcoming....Larry

[MoMo]

Dropped the motor off, owner says no problem, as strynboen says it is not in a critical area so I'm quite confident it'll work...Larry

Will he put a fresh piece of cast aluminum into it ?

No, it will be filled.  I'll have to do the finishing but as long as it is strong and sturdy I won't be all that concerned with the aesthetics of the motor.  Function over form.  This will probably be the last 400F and wind up as a keeper if all works out well...Larry

[MoMo]

The Macbook Air my daughter gave me quit this morning so posts may be less frequent ,  as I'm back to my crappy old, slow HP-it had been a joy going back to Mac.Larry

[grcamna2]

Dropped the motor off, owner says no problem, as strynboen says it is not in a critical area so I'm quite confident it'll work...Larry

Will he put a fresh piece of cast aluminum into it ?

No, it will be filled.  I'll have to do the finishing but as long as it is strong and sturdy I won't be all that concerned with the aesthetics of the motor.  Function over form.  This will probably be the last 400F and wind up as a keeper if all works out well...Larry

A nice finished area is possible w/ careful Dremel work and a sanding block w/ different grades of emery paper. 
That's clean looking front wheel Larry.

[MoMo]

The Macbook Air my daughter gave me quit this morning so posts may be less frequent ,  as I'm back to my crappy old, slow HP-it had been a joy going back to Mac.Larry

Do tell! Hard drive dead or the power unit? I've used them for 30 years and knock wood, haven't lost a day because of them. And have "resuscitated" quite a few.

it was totally dead, now it comes on but will not take my password.  Just sits locked up at the screen.  I had used Macs in my photo lab/studio and never had a problem with them.  The HP I own is sluggish to say the least...Larry

[SOHC4 Cafe Racer Fan]

Give this a whirl:

https://support.apple.com/en-us/HT201314

Cal -- not only a motorcycle wiring and electronics guru BUT also Apple tech support!! What the heck is going on with OS updates anyway?!

[MoMo]

Thanks for the link but my daughter took the Mac over to a friend who supposedly is a computer guru.. Hope so

[David B]

Hi Larry,

Just stumbled across this thread. Looks like lunch is DEFINITELY on me next time.  . I never noticed the damage to the engine case either. I would have probably just pushed the damn thing into the river if I had. I did find the indicator console I mentioned so I'll drop it in the mail. Following this one for sure now!

Dave

[MoMo]

Hi Larry,

Just stumbled across this thread. Looks like lunch is DEFINITELY on me next time.  . I never noticed the damage to the engine case either. I would have probably just pushed the damn thing into the river if I had. I did find the indicator console I mentioned so I'll drop it in the mail. Following this one for sure now!

Dave

Glad you found the thread David.  Definitely a bit worse than I thought it'd be but I think I can make a go of it.  Definitely will need the cluster, I look forward to seeing you again sometime soon.  On my way to get the motor, then on to work to use their parts cleaner for the front forks. Regards...Larry

[MoMo]

From this

 To this

[grcamna2]

Good to see that filled,looks like aluminum rod arc welding.That should smooth out,how's the inside look ?

[MoMo]

Took the motor to a local Amish aluminum fabricator.  I had a 750 KO on which the carb  bracket broke and he repaired it for the outrageous sum of $5 several years ago.  This time he welded the motor, another bracket I made for the Pink Panther 400 and attached a gazing globe to a bracket. He had the balls to ask for the outlandish sum of $30 .  I couldn't let him get away with that so I gave him $40-still not enough but 25% more than he wanted.

After a bit of grinding and sanding on my part


I had to grind a bit in order for the cover to fit, which it now sits flush.


The alternator cover was pretty beat so I took some 60 grit emery to it.  At one time I had a mint spare cover and alternator-think I sold it on Ebay.



Both cover and motor cases are sitting overnight with JB Weld to fill some of the crooked nannies(whoops, I mean nooks and crannies).