22-08-2018, 01:14 PM
(This post was last modified: 22-08-2018, 01:46 PM by Steve Jones.)
I've repaired a fair few of these in a similar state to that described indeed at one time I was buying up damaged ones to repair. My method doesn't involve welding/brazing nor any lathe work but ends up with a repaired front cover that is indistinguishable from the real thing when fitted and is also stronger. Photo below is of a repaired cover fitted to my Ulster.
You start with two pieces of exhaust tube. First is 24mm I/D, 2 1/2" long. Second is 38mm O/D, around 1" long depending on the length of the missing piece on your casting (please excuse the mix of units).
The longer piece is inserted into the cleaned up casting such that it's front edge is in line with the remaining nose of the casting. Mix up some epoxy metal/plastic metal stuff and fill the missing piece of the casting. Once it's gone off, shape the repaired area such that it is now the size the casting would have been if it hadn't been broken. Continue to shape the end of the casting/repair such that the shorter length of tube will fit snugly over it. Glue in place with your favourite epoxy glue/putty and, when all cured, dress the exposed end of the casting/repair flush. Finally, paint the exposed piece of tube with aluminium paint.
It's all rather easier to do than to describe but, as they used to say on 'Blue Peter' here's one I did earlier that should make things clearer.
Steve
You start with two pieces of exhaust tube. First is 24mm I/D, 2 1/2" long. Second is 38mm O/D, around 1" long depending on the length of the missing piece on your casting (please excuse the mix of units).
The longer piece is inserted into the cleaned up casting such that it's front edge is in line with the remaining nose of the casting. Mix up some epoxy metal/plastic metal stuff and fill the missing piece of the casting. Once it's gone off, shape the repaired area such that it is now the size the casting would have been if it hadn't been broken. Continue to shape the end of the casting/repair such that the shorter length of tube will fit snugly over it. Glue in place with your favourite epoxy glue/putty and, when all cured, dress the exposed end of the casting/repair flush. Finally, paint the exposed piece of tube with aluminium paint.
It's all rather easier to do than to describe but, as they used to say on 'Blue Peter' here's one I did earlier that should make things clearer.
Steve