How to fix tiny hole in crankcase cover?
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How to fix tiny hole in crankcase cover? podi2NOSPAM 04-24-2006
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Posted by on April 24, 2006, 10:58 am
I'm hoping I could get some ideas on how to fix a tiny hole I see
on my bike's crankcase cover. I can't imagine how this came into being
because all I see is a small rectangular projection that juts out from
the cover, as if the previous owner tried to push the it out with a
screwdriver from inside, leaving a *tiny* hole. The result is that I
would see, during the course of a night, a few drops of oil on the
garage floor

I have decided to take the cover out and see for myself what it is
exactly but, I hope someone who may have had similar damage could
describe how to fix this hole.

How about soldering, or spot-welding the hole? Given that the material
is aluminum, would it work? Since I'm not a welder, is there something
off the shelf I could use to plug it?

Thanks.

Posted by IdaSpode on April 24, 2006, 11:32 am
On Mon, 24 Apr 2006 07:58:08 -0700, podi2NOSPAM@yahoo.com wrote:

>I'm hoping I could get some ideas on how to fix a tiny hole I see
>on my bike's crankcase cover. I can't imagine how this came into being
>because all I see is a small rectangular projection that juts out from
>the cover, as if the previous owner tried to push the it out with a
>screwdriver from inside, leaving a *tiny* hole. The result is that I
>would see, during the course of a night, a few drops of oil on the
>garage floor
>
>I have decided to take the cover out and see for myself what it is
>exactly but, I hope someone who may have had similar damage could
>describe how to fix this hole.
>
>How about soldering, or spot-welding the hole? Given that the material
>is aluminum, would it work? Since I'm not a welder, is there something
>off the shelf I could use to plug it?

JB Weld or a similar two part metallic epoxy.

My DRZ400S fell over in my driveway, poked the shift lever through the
left side case. Removed it, cleaned well with degreaser, roughed up
the surface with a dremel tool, puttied it up, smoothed it as the
epoxy set. If it weren't slightly darker than the case color you'd
never be able to tell the repair was there.

>Thanks.

DJ

Posted by chateau.murray@btinternet.com, on April 24, 2006, 11:42 am

IdaSpode wrote:
> On Mon, 24 Apr 2006 07:58:08 -0700, podi2NOSPAM@yahoo.com wrote:
>
> >I'm hoping I could get some ideas on how to fix a tiny hole I see
> >on my bike's crankcase cover. I can't imagine how this came into being
> >because all I see is a small rectangular projection that juts out from
> >the cover, as if the previous owner tried to push the it out with a
> >screwdriver from inside, leaving a *tiny* hole. The result is that I
> >would see, during the course of a night, a few drops of oil on the
> >garage floor
> >
> >I have decided to take the cover out and see for myself what it is
> >exactly but, I hope someone who may have had similar damage could
> >describe how to fix this hole.
> >
> >How about soldering, or spot-welding the hole? Given that the material
> >is aluminum, would it work? Since I'm not a welder, is there something
> >off the shelf I could use to plug it?
>
> JB Weld or a similar two part metallic epoxy.
>
> My DRZ400S fell over in my driveway, poked the shift lever through the
> left side case. Removed it, cleaned well with degreaser, roughed up
> the surface with a dremel tool, puttied it up, smoothed it as the
> epoxy set. If it weren't slightly darker than the case color you'd
> never be able to tell the repair was there.
>

What he said. Use that Chemical Metal aluminium powder-based epoxy. You
have to get the cases utterly, utterly clean for it to stick - I mean,
any oil at all, and it'll fall off - but it is incredible stuff.


Posted by FB on April 24, 2006, 12:17 pm

podi2NOSPAM@yahoo.com wrote:

> How about soldering, or spot-welding the hole? Given that the material
> is aluminum, would it work? Since I'm not a welder, is there something
> off the shelf I could use to plug it?

The entire pressure vessel of the Apollo command module was bonded
together with 3M 2-part epoxy and the epoxy-to-aluminum bond joints had
to withstand 11 times the force of gravity on splashdown. So you know
that stuff is very strong, it ain't Bondo.

JB Weld is a readily available commercial 2-part epoxy that is
impervious to gasoline or oil.

Clean the surface with methyl alcohol, brake cleaner, or carburetor
cleaner and roughen the surface. Mix the JB Weld so it's dark grey and
position a heat lamp to help it cure faster. The repair will stay in
place forever if the parts were properly cleaned and roughened.


Posted by slguy on April 24, 2006, 1:20 pm
Many, many thanks to all.


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