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1Back to top Go down    How can I safely weld? on Tue Oct 02, 2018 9:00 pm

Blackthumb

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Hi, trying to remove waterpump plug, she's stuck fast & rounded off, I've tryed all sorts get it out! Was thinking as last resort to mig weld a nut on it may be but I'm not sure on how safe for the electronics and bearings this will be. Also have a small crack in manifold to mig... Any advise please! 😵

    

2Back to top Go down    Re: How can I safely weld? on Tue Oct 02, 2018 9:13 pm

duck

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Have you tried an Easy-Out? (Or whatever you call them over there.)


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

3Back to top Go down    Re: How can I safely weld? on Tue Oct 02, 2018 9:19 pm

Blackthumb

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I think there called screw extractors over here. I haven't tryed that yet, I have a feeling it will either shear off the extractor or chew up the nut as its stuck fast. The hex rounder out unsing impact driver on high torque low speed!

Was thinking about maybe tapping a left hand tightening bot in there but I'm not sure of the depth I can drill?

    

4Back to top Go down    How can I safely weld on Tue Oct 02, 2018 9:56 pm

redrockmania

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Easi-Outs are of varying quality. If you are going do this go to an engineering supplies shop and buy the best quality. I have had cheaper Easy-Out type extractors break. I presume you have tried gentle hammering, heat and liquid chemicals in attempting to release the stubborn plug.
Welding: If you are not confident in you MIG welding skills, you risk doing damage to the Ali. surrounding the stuck plug - better to get a skilled welder/mechanic to do it. If doing it yourself, first disconnect and remove the battery and disconnect wiring connections to key electronics - esp the CPU and EFI computers. Put protective covering anywhere where weld spatter is likely to cause damage.
a 3rd Option: If you careful drill a small centered hole in the plug and then progress with larger drills you will end up with only a small amount of remaining plug left. It is possible then to use a cold chisel of suitable size to tap on the remaining plug counter-clockwise and remove it. Alternatively with only a small amount of plug left you can tap it in sections inwards with will break off the remaining plug and should leave the Ali casting thread intact - Good Luck.

    

5Back to top Go down    Re: How can I safely weld? on Tue Oct 02, 2018 10:44 pm

Blackthumb

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Excellent suggestions redrockmania! I am a pretty confident Welder, I just don't like doing it if I can avoid when there are electronic systems and bearings involved 🤪

I'm gonna try..

1 extractor
2 tap
3 drill
4 weld

    

6Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 1:52 am

duck

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Some other tricks to try:

Soak with penetrating oil.

Heat it up with a butane torch.

Vise-Grips

Pounding a high quality Torx bit into a stripped Allen head has been known to work.

And swearing. Lots and lots of swearing. Very Happy


I had a temp sensor break off in that hole over the summer when removing it for a coolant change. An Easy-Out did the trick with surprisingly little torque.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

7Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 3:57 am

MartinW

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Heat it up and use a quality Torx bit in an impact screwdriver, and hit it with Thors hammer while cursing in old Nordic.
Regards Martin.


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K75s Hybrid
    

8Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 10:56 am

Point-Seven-five

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I have had pretty good luck with stuck Allen head fasteners by using Torx bits and a pneumatic impact wrench.

The Torx bits are very hard and there are sizes that are a bit larger than Allen so I can drive the bit into the stripped out head without having to drill it out. In fact, what's left if the Allen socket gives a great bite. The impact wrench does a great job of jarring the seized fastener loose. A little bit of heat around the fastener helps a lot, too.


__________________________________________________
Present:
1994 K75RT
1994 K75S
1992 K100RS

Past:
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

9Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 12:14 pm

duck

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@MartinW wrote:Heat it up and use a quality Torx bit in an impact screwdriver, and hit it with Thors hammer while cursing in old Nordic.
Regards Martin.

How to swear like a Viking:
https://kellyaevans.com/swearing/


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

10Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 7:10 pm

92KK 84WW Olaf

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@duck wrote:Some other tricks to try:

Soak with penetrating oil.

Heat it up with a butane torch.

Vise-Grips

Pounding a high quality Torx bit into a stripped Allen head has been known to work.

And swearing. Lots and lots of swearing. Very Happy


I had a temp sensor break off in that hole over the summer when removing it for a coolant change. An Easy-Out did the trick with surprisingly little torque.

Best bet is slacken off the bottom hose clamp and drain it that way. The drain plug and temp sensor in the drain plug hole seem to have a habit of going wrong.


__________________________________________________
1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 84,600 miles
1983 K100RS 0011175 Fricka 29,000 miles Damn K Pox
    

11Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 8:58 pm

duck

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Best bet is slacken off the bottom hose clamp and drain it that way. The drain plug and temp sensor in the drain plug hole seem to have a habit of going wrong.

I no longer do that. A few years ago I did that on my K1100RS. A couple of hundred miles later the hose blew.




Had to take the belly pan, seat and tank off in a parking lot to do a ghetto repair and refill it.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

12Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 9:17 pm

Dai

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Give the easyouts a miss. They will break and then you're stuck with a piece of high-carbon steel that you can't drill. I know this is a stupid question, but have you tried using a side-drive socket? In most cases they will deal with a rounded nut as long as there is some flat bit left.

https://www.ebay.co.uk/itm/Silverline-826021-Impact-Socket-1-2-Drive-6-Point-Metric-32mm/263856150360?epid=22022099146&hash=item3d6f0d5758:g:mQIAAOSwhUtbZEa4

Yes, it's an impact socket (!!) but it was the best pic I could find that illustrates the curved walls and the hex-cutaway. Just about all of my sockets are 6-point side-drive because it's very difficult (but not impossible) to round off nuts with them.

Otherwise, I'm with the smack-a-Torx-drive-with-a-big-'ammer brigade.

Duck: that looks like sheer bad luck.

[Edit]. Oh bollocks - we were talking about an allen bolt with the inside rounded off, weren't we? Never mind - it's all good info anyway! Laughing


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

13Back to top Go down    Re: How can I safely weld? on Wed Oct 03, 2018 9:31 pm

duck

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@Dai wrote:Duck: that looks like sheer bad luck.

That's not bad luck. It's causality. That's exactly where I held the hose to pull it off for draining. And it failed shortly thereafter.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

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