Devastated

[Sgtbiro]

Hi just found a hair line crack in my Dragonfly’s gearbox about 3” long round the kick start housing, what’s the prognosis anyone is it terminal or is it fixable.

Cheers Kevin.

[EW-Ron]

We feel your pain !

Such matters are never beyond repair - you just need to find the expertise to tackle it.
Just being 'just'.
And we've not seen the actual item ....

Bigger small local airports often have an alloy welding service.
These guys can weld ANYTHING - things that fly need to be GOOD.

You are likely to need to end up with a big ugly fillet weld - to keep some strength in that area.
Better that than scrapping it ?
Hopethishelpsalittle.

[EW-Ron]

If say you were in the Brum area, there are half a dozen welders of alloy that advertise.
Inc some that say free quotes.

A difficulty is that the alloy itself may be of unknown parentage.
And possibly permeated with oil

Its unlikely they will want to weld it in situ and assembled.
So a full stripdown is in your future !

[patrickwhitty]

When I bougth my first car, a 1952 Riley which I still have, the aluminium bell housing was cracked all round the starter motor mounting.  My father was doing a welding course at the time and asked his tutor about welding aluminium. 'Bring it in' he said, and welded it, good as new, and I sent him the suggested beer money. It does have a big fat weld which is much less visible than a gearbox repair but does it really matter? A big fat weld is part of the gear box's history. Maybe it matters for a super shiny show bike. I'm sure you will find someone local who can weld it.