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Buell Forum » Old School Buell » Archive through October 14, 2009 » Weld and retap header bolt « Previous Next »

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Blackandchrome
Posted on Sunday, October 04, 2009 - 07:40 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Top left exhaust stud bolt on the front head. 2002 X1 lightning

The helicoil stripped out of my header bolt and I'm trying to figure out the best way to fix it.
I was thinking drilling to the next bolt size, but a 7/16" bit is loose in the opening. I don't think there's enough room to go to a 1/2" bolt.

Has anyone been able to weld it without removing the heads from the bike? If so, anything special I need to look out for?

I have a full time welder where I work and can get him to do it if I tell him how. Can he use any type of aluminum filler or does he need to be specific to the head's alloy (anyone know what it is?)

Could I just shift the flange 90 degree and drill two new holes?
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Drhacknstine
Posted on Sunday, October 04, 2009 - 08:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

+1 on the shift 90 degrees. Seen this done to many big twins and sportsters alike.
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Oldog
Posted on Monday, October 05, 2009 - 12:19 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

dont think you can go 90 look at all possible obstacles before cutting metal

weld up is do-able, had front mount fixed by cyclerama..
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Smoke
Posted on Monday, October 05, 2009 - 06:00 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

it's always recommended to remove the head for welding it up. prevents stray arcing in bearings or other parts you don't want stuck together. otoh i've seen it done many times. good luck!
tim
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Blackandchrome
Posted on Monday, October 05, 2009 - 11:00 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I was able to get it welded on the bike this morning. I moved the gas tank as far back as I could and disconnected the positive terminal on the battery.
We grinded a small section of the head near the welding location for a solid ground.

I'm dropping the bike off to get it drilled and tapped tonight. Hopefully everything goes smooth.

Looking at it again, welding is much better than shifting it 90 degrees. It MIGHT be able to fit, but there isn't alot of aluminum holding it.
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