Stripped exahust thread repair?

[srcarr52]

This is not the way to do it. 1/4x20 steel nut zerts and lots of loctite.

Before Christmas R2D put up a thread of how to repair this 2100 so feeling in the Christmas spirit I offered to fix it for free. Fast forward to late February and a it finally arrives on my door step. First step... get the remaining insert out and survey the damage.

I think inserts are out of the question now.

 

[Fish]

not much left to work with, it looks like it is time to cut slots in the sides and convert it to use square headed bolts with the nuts put on from the front.

Why????

 

[srcarr52]

Welding it up is the only option. So ditch cut and bead blast. I prefer to weld from the inside of the exhaust port so the outside and fins are left hopefully untouched.

How do you weld something so deep? First step... forget everything you ever learned about electrode stick out for tig welding. Turn up your gas flow and use a good gas lens to keep everything properly shielded.

After welding.

After sanding flat on the belt sander.

 

[srcarr52]

After cleaning up the welds inside and around the edge.

 

[Fish]

cool, go for it!!!!

That ugly piston look better up top?

 

[srcarr52]

I was really feeling in the Christmas spirit so I also offered to port it, so a little more grinding to be done. Sorry no before pictures just after porting.

 

[barneyrb]

Nice job on the repair......I wish I had a machine and talent for welding alum.....

 

[srcarr52]

I went together with a much better used thin ring piston and new rings. Clean looking air filter cover.

 

[srcarr52]

nice..that is what a guy with the proper equipment and welding skills can do.

any concern about the heat warping the bore out of round?opcorn:

Nope. I've welded a lot of stock cylinders with no warping. I've measure before and after with a very accurate bore gauge and I haven't seen enough warping to worry about. AM cylinders are a different story, those wander all over the place when welded on. I had a NWP BB kit tighten up 0.005" on the cylinder extensions just being welded on.

 

[srcarr52]

And since a everyone always demands a video. The bar is a 34", RSLHK chain (half skip), and 8 pin sprocket in about 28" of sycamore.

[video=youtube;biLq1NXY00A]https://www.youtube.com/watch?v=biLq1NXY00A[/video]

 

[tpope]

Nice repair

Sweet work. Thanks for sharing.

 

[Jacob J.]

Iowa Mafia gettin' er done.

 

[srcarr52]

Iowa Mafia gettin' er done.

That's how we do it around here.

 

[Mo. Jim]

Nice work Shaun,as always. Hedgefest is fast approaching,hunting parts and cleaning saws.

 

[srcarr52]

Nice work Shaun,as always. Hedgefest is fast approaching,hunting parts and cleaning saws.

I'm good on parts... Short on time.

 

[Jimmy in NC]

And since a everyone always demands a video. The bar is a 34", RSLHK chain (half skip), and 8 pin sprocket in about 28" of sycamore.

[video=youtube;biLq1NXY00A]https://www.youtube.com/watch?v=biLq1NXY00A[/video]

Looks great Shaun. Truly top notch work there as always.

 

[Chris-PA]

Very nice work! I wish I had the skills and equipment for welding aluminum.

 

[belgian]

Yup, very nice work.

I fixed a jug of a contra super the same way, and ended up quite nicely. Not as nice as yours, but hey, this is only the belgian mafia....:hmm3grin2orange:

 

[Jeff Lary]

Very impressed, great work I bet he was thrilled with it,.... I know I would be !

 

[ErikTheRed]

Sweet J***s!

That's some nice torch work.
Not to mention the finishing.