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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
Cracked 'A' Crankcase - Large Idler Boss
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<blockquote data-quote="A_HRD" data-source="post: 3747" data-attributes="member: 49"><p><strong>Hard to Get At!</strong></p><p></p><p>Thanks so much for all the replies! (It was something of a surprise as I wrote the initial plea for help about 10 months ago!). But it remains relevant as I have done nothing about it thus far - too many other projects...</p><p></p><p>The trick with a Series A case is that there is no timing-cover! The crankcase folds around the timing chest and forms its own rigid box section for added bottom-end strength. Take a look at a photo sometime. So to repair the large idler boss by whatever means, it has to be done 3.5 inches down through a 1-1/4 wide slot at cylinder base level. Or through a similar sized hole behind the external oil-pump. </p><p></p><p>Alloy welding is probably out because of access issues; metal stitching sounds interesting and I have seen it done very effectively on a Series A cast iron head. Alternatively, I could bore out the boss and insert an interference fit bush to strengthen the area; "stop-drilling" might also be needed as the crack goes on through the oil-hole and out the other side for about 3/16ths inch. And dye penetrant might be needed to ascertain the true end-point of the crack. So all of your comments are relevant - thank you very much for the assistance. </p><p></p><p>Of course, any other thoughts would still be welcomed....</p><p></p><p>Peter Barker</p><p>Bristol, UK.</p></blockquote><p></p>
[QUOTE="A_HRD, post: 3747, member: 49"] [b]Hard to Get At![/b] Thanks so much for all the replies! (It was something of a surprise as I wrote the initial plea for help about 10 months ago!). But it remains relevant as I have done nothing about it thus far - too many other projects... The trick with a Series A case is that there is no timing-cover! The crankcase folds around the timing chest and forms its own rigid box section for added bottom-end strength. Take a look at a photo sometime. So to repair the large idler boss by whatever means, it has to be done 3.5 inches down through a 1-1/4 wide slot at cylinder base level. Or through a similar sized hole behind the external oil-pump. Alloy welding is probably out because of access issues; metal stitching sounds interesting and I have seen it done very effectively on a Series A cast iron head. Alternatively, I could bore out the boss and insert an interference fit bush to strengthen the area; "stop-drilling" might also be needed as the crack goes on through the oil-hole and out the other side for about 3/16ths inch. And dye penetrant might be needed to ascertain the true end-point of the crack. So all of your comments are relevant - thank you very much for the assistance. Of course, any other thoughts would still be welcomed.... Peter Barker Bristol, UK. [/QUOTE]
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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
Cracked 'A' Crankcase - Large Idler Boss
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