Author Topic: T35 frame crack repair?  (Read 1043 times)

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Offline douglas1947

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T35 frame crack repair?
« on: 23 May 2023 at 06:10 »
Yesterday I have noticed a frame crack (typical?) on my MK1.
What is the best way to repair the frame?

Michael



Image converted to linked file and aspect ratio corrected - Dave - 22June2023
« Last Edit: 21 Jun 2023 at 17:42 by Dave »

Offline douglas1947

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Re: T35 frame crack repair?
« Reply #1 on: 23 May 2023 at 06:12 »
Crack above the left side bracket for swinging arm bush.

Offline eddie

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Re: T35 frame crack repair?
« Reply #2 on: 23 May 2023 at 08:47 »
Michael,
             This is the method I have used to repair similar breakages. Firstly, clean back to bare metal the area around the break. Carefully trim back the lug until you have at least 5-6mm of tube clear of the lug. Very carefully, clean up the tube so that there is no sign of the brazing on the exposed tube (any braze will contaminate the subsequent welding, leaving a brittle joint). 'V' out the joint by just over half the tube thickness, and if possible, fit a thin sleeve inside the tube (to keep the ends lined up). Get a welder to 'Argon Arc' the ends together again. After fettling the joint, build up the lug again to it's original shape (either with silicon bronze weld, or body filler (just for cosmetic purposes)).
   Having made the repair, make sure it is not going to re-occur - a contributing factor to these cracks is often poor lubrication of the swinging arm pivots. You will find that, if still fitted with the original pivot pins, they are drilled right through - resulting in the use of the grease gun pushing the sealing plug out of the end of the swinging arm lug (rather than pushing grease into the bearing). If the sealing plug is already out, press a tight fitting plug into the end of the pivot pin, then fit a new sealing plug. If you need to push a sealing plug out, remove the retaining plug/grease nipple from the outside of the pivot, and use a drift to push the plug out.

  I hope this all makes sense,
                                           Regards,
                                                         Eddie.

Offline douglas1947

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Re: T35 frame crack repair?
« Reply #3 on: 31 May 2023 at 06:45 »
Eddie,

many thanks for your helpfull advises.
I have now started stripping down the bike, but must find someone for TIG welding.

I thing about the construction of the early frame type (MK1+3).
There is above the the swinging arm lug the small wellded / brazed? on triangle to bolt on the back frame.
This brings also negative side pressure to the frame tube.
May be, it is good to enlarge the triangle down to the lug?

Michael

Offline douglas1947

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Re: T35 frame crack repair?
« Reply #4 on: 31 May 2023 at 06:55 »
I add a photo of the MK1 frame rear.

Offline douglas1947

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Re: T35 frame crack repair?
« Reply #5 on: 21 Jun 2023 at 09:37 »
Bad news!
Yesterday I put off the engine / gearbox out of the frame and noticed further frame breaks.
The right hand tube, containing theon both ends torsion bar is cracked on bothe ends of the lugs.
On left hand side there is "only" a breakage at the rear lug.
I wonder how I got the bike home the last ride!

Has anyone experience with repairing the frame on so many tubes? The torsion bar tube do not have space for an extra inside repaire tube, neeing spacefor the torsion bars.

I have no idea, what to do.

Michael



Image converted to linked file and shadow detail increased - Dave - 22June2023
« Last Edit: 21 Jun 2023 at 17:45 by Dave »

Offline douglas1947

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Re: T35 frame crack repair?
« Reply #6 on: 21 Jun 2023 at 09:40 »
Breaks on rear sides, right and left.





Images converted to linked files and aspect ratio corrected - Dave - 22June2023
« Last Edit: 21 Jun 2023 at 17:48 by Dave »

Offline douglas1947

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Re: T35 frame crack repair?
« Reply #7 on: 10 Jul 2023 at 07:41 »
I have still no idea, what to do.
A friend told, he had no good results with "rebrazing" tubes out of the frame lugs.
Has anyonetriedto bore / grind out the broken frame tubes out of the lugs?

Michael

Offline Daren W Australia

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Re: T35 frame crack repair?
« Reply #8 on: 10 Jul 2023 at 08:52 »
Hi Michael

Try this www.douglasmotorcycles.net/index.php?topic=2696.

Always search the forum it has probably been discussed before.

Regards Daren
too many dougli not enough time!

Offline douglas1947

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Re: T35 frame crack repair?
« Reply #9 on: 15 Jul 2023 at 08:37 »
Hi Daren,

thanks for this helpfull advise.

Michael