Author Topic: 550 cylinder cover repair  (Read 869 times)

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Offline TwoTired

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550 cylinder cover repair
« on: September 27, 2021, 08:02:39 AM »
Hi all.  Does anyone have some experience using the Caswell aluminum repair rods?

I have a CB550 cylinder cover that was pried off by the selling parts breaker with a single screw remaining, breaking off the screw hole tab into the seal channel .
This is the updated cover with shaft lock pins in otherwise fine condition.

The area to be repaired is not a high stress area.  So, I was wondering if the Caswell repair rods could be used to build up the area to be machined and shaped back to useful condition.

Anyone used these?

Cheers,
Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

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Offline pekingduck

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Re: 550 cylinder cover repair
« Reply #1 on: September 28, 2021, 02:53:30 PM »
I would definitely have the cover welded rather than "mended".  The Caswell rods are for fusing with pot metal, not aluminum.

Offline TwoTired

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Re: 550 cylinder cover repair
« Reply #2 on: September 28, 2021, 04:20:04 PM »
I would definitely have the cover welded rather than "mended".  The Caswell rods are for fusing with pot metal, not aluminum.
This from Their Web Site:

Casweld™ AL Aluminum Brazing Rod
Designed for joining all brazable grades of aluminum sheet, plate, tubing and piping, extrusions, rod and wire
5 Rod Kit (1/8" x 18") & 2 oz Flux

Perfect for:

    Aluminum Castings

    Filling Holes

    Building Up Worn Sections Joining Cast To Wrought

    Joining Thick Parts to Thin Parts
    Casweld™ AL can be anodized

Tensile Strength: up to 35,000 PSI (250 MPa)
Bonding Temperature: 800F - 1000F


I was looking for Some Experience with this.
I don't have the broken off piece.  So it would have to be built up and shaped to function correctly.

Cheers,


Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.

Offline Flyin900

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Re: 550 cylinder cover repair
« Reply #3 on: September 28, 2021, 05:09:03 PM »
Since that is not a bolt down area I would also consider a product called Tech Steel. I have rebuilt broken off fins on a couple of motors by fabricating a wire scaffold and building up the Tech Steel over the framework.
Obviously a weld style repair will be the strongest and best solution, yet by micro drilling into the broken surface to allow the Tech Steel to penetrate the holes and grab better it could be another solution for the fix.
Here are a few pictures of the fin repairs and the Tech Steel product. It is superior to the JB Weld by a quicker cure time and a higher temp rating of 500F.
« Last Edit: September 28, 2021, 05:10:48 PM by Flyin900 »
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1972 CB350F - Candy Bacchus Olive - Super Sport
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Offline TwoTired

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Re: 550 cylinder cover repair
« Reply #4 on: September 28, 2021, 10:02:07 PM »
That look great flyin.  But this is a bolt down location.  The cover was pried off with bolt still in place leaving the tab and hole for the bolt behind.  I was refunded the money I paid for it, as the seller determined it was a total loss.  Which it is unless a repair can be effected.  Sure seems possible.  Just not sure I have the skill, though.

I’ll have to look around for a welder in the vicinity.  Not sure just where though.

Cheers,
Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.

Offline grcamna2

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Re: 550 cylinder cover repair
« Reply #5 on: September 28, 2021, 11:16:12 PM »
I'd like to know more about that Caswell AL aluminum brazing rod product;it seems like good quality.
I'm sure a Tig welder who often works with cast aluminum will fix that cover for you TT.
Can you check to see if the bottom surface of that rocker cover is still flat(just in case the PO warped it by forcing it off)by putting it on a machined cast iron table and checking it all around with a fine feeler gauge ?
I had crankcases Tig welded at a Technical High School in Indiana,PA. when i lived there by a shop class and the teacher prepped the parts to be done in an oven multiple times.He kept putting the parts in an oven until the cast aluminum parts stopped having oil come-out from the aluminum pores.He said this was necessary before Tig welding the parts together.The parts came out very nice and I'm sure the oven was necessary.
TT,I doubt you'll have much oil where the piece broke off as it's a fresh break,it doesn't look like anyone drove the bike around after it was broken? The engine cases I had were damaged on the base of the engine and had sat with old sludgy engine oil seeping through them for years. TT,you'll be fine to have that piece Tig welded back on.  ;)
I think your broken bolt mount on that top rocker cover will fit together exactly to match-up for a good,true fit,imo.

The only problem I had with their HS class doing the repair was they were vertically split crankcases and the repair/shop teacher was told by me "only weld UP TO the factory split on both cases,I'll work with the rest" because the flat factory machined split was where the cases fit together and those areas were in good condition(a dirt bike engine)and it had a gasket between the vertical split on both cases. They didn't follow my directions and welded all the way around the cases  ::)
« Last Edit: September 29, 2021, 01:46:22 PM by grcamna2 »
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Offline RAFster122s

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Re: 550 cylinder cover repair
« Reply #6 on: September 29, 2021, 03:51:29 AM »
Calj737 has experience TIG welding cases and such. Maybe reach out to him for some advice on the rods or materials to use to effect the repairs.
Definitely have to purge the oil from the casting as the welding instructor had done. I recall Calj mentioned that was needed…
David- back in the desert SW!