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Old 11-09-2006, 02:29 PM   #1
andrave
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Can you weld an aluminum frame/fairing stay bracket?

Hey guys I was putting my front fairing on and it started wiggling and I realized that the bracket for the fairing stay was broken (apparently at some point a previous owner put some epoxy on it or something to hold it in place).

I know this is aluminum, which is tricky to weld. Can this be welded? What is the appropriate repair technique? Anyone know a place that could do it for a reasonable price?

My experience having TIG welds done on intercoolers is that very few people have expertise/experience in this area and this is something I need done right the first time.
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Old 11-09-2006, 02:31 PM   #2
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that indeed looks tricky, gl man.
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Old 11-09-2006, 02:32 PM   #3
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That's an easy weld. Just pick any welding shop out of the phone book & they can probably handle that one. Aluminum is tougher to weld than steel, but that 's a nice thick piece. Also, its rather hidden so it doesn't have to be pretty & it doesn't hold a very big weight load.
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Old 11-09-2006, 02:34 PM   #4
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Do you think so? I mean when you are riding 100 mph plus I'm guessing there is significant strain on that piece due to the air flowing over the fairing and windscreen. Not to mention its the only thing holding up the rathy weighty stay/mirror/fairing/headlight/cluster/windscreen combination when you hit big bumps (or smack the front end down after a power wheelie).

I know that both pieces are thick so it should be easier to weld than thin aluminum but I think its still gonna be a difficult weld.
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Old 11-09-2006, 02:34 PM   #5
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It can be welded with a hilliark welder but it will cost you allmost the amount of the fairing stay
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Old 11-09-2006, 02:35 PM   #6
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Old 11-09-2006, 02:37 PM   #7
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its not the fairing stay thats broken its the frame.
if it was just the fairing stay I'd simply order a new one.
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Old 11-09-2006, 02:41 PM   #8
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I know its not going to be cheap.. I'm guessing that single weld will cost me anywhere from $50-$100. Does anyone know a shop or welder that has welded on aluminum bike frames before?
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Old 11-09-2006, 02:41 PM   #9
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Lets see here....

2 choices are obvious....

1) run without that part holding the bracket....
2) adhere the tab back to the frame (welding it would be the best choice)
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Old 11-09-2006, 02:41 PM   #10
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Quote:
Originally Posted by andrave
its not the fairing stay thats broken its the frame.
if it was just the fairing stay I'd simply order a new one.
Then that should be no prob. It would take 5 mins to do just ask a welder if they have a hilliark welder mine is in vegas or i would do it for free
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Old 11-09-2006, 02:42 PM   #11
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Old 11-09-2006, 02:49 PM   #12
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I can tig/mig. But your best having a "real" welder do it
It is harder to weld than steal, the main reason why is that when welding steal, you can tell how hot your getting because steal glows red, you know basically how much heat your putting down, and you can see your bead, were as with aluminum it does not glow, so burning through is the big concern. Temperature control is the trick to welding aluminum I think. That looks like pretty thick cast aluminum, so a good medal/weld shop should be able to take care of it for around the cost of a 12 pack or so
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Old 11-09-2006, 02:50 PM   #13
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The real problem is going to be that it is cast aluminum. Might want to mention that to your welder.
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Old 11-09-2006, 02:51 PM   #14
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metric can weld alu

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Old 11-09-2006, 02:52 PM   #15
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Quote:
Originally Posted by Moody
The real problem is going to be that it is cast aluminum. Might want to mention that to your welder.
Yeah, cast sucks.. thats going to add a few bucks to the cost I'm sure
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Old 11-09-2006, 02:53 PM   #16
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metric can weld alu

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Problem solved!
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Old 11-09-2006, 03:00 PM   #17
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Old 11-09-2006, 03:01 PM   #18
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Nevermind....

Sounds like Patrick's got you headed in the right direction

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Old 11-09-2006, 03:26 PM   #19
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cool thanks.

and for the record I weld steel on a regular basis i have an arc and I have access to various migs both shielded and non shielded though I usually work more with the hobby style ones.
I just have never tried aluminum.. I know I can get aluminum sticks for the arc welder but something tells me this isn't the time to learn... lol
I'll end up with holes in the frame.
I know its cast but it is factory tig welded to the frame spars so I know it can be welded. I'm surprised they didn't make that bracket bolt onto the frame since I'm guessing its a relatively common place to receive damage.

I'll give patricks number a ring and see if he can do it next week.

thanks all
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Old 11-09-2006, 03:28 PM   #20
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Yep, cast aluminum is tricky. Pay someone to show you the tricks for the first time out.
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