Another view of plates, the alternator cover was fitted and used as the template for the form. All infill plates were taken from 4mm aluminium sheet.
After welding the crankcase was put up on milling machine and a light skim taken off. All of the M6 tapped holes were reinstated and the lower dowel location machined in place, unfortunately the dowel location was slightly out and had to be re done. The engine is now back in the bike and was fired up last Saturday and all is fine, wish we had gone down this road in the first place instead of putting time and money into another motor. Hindsight is a wonderful tool to have in the toolbox.
Not easy that, a lot of skill to repair! Good job, I love it when people use their head and skills etc, makes a change in a throw away world to see something get saved.
Thanks guys, yes a lot of time but this is what we do for a living, normally paying customers though.
We still have to open up the low mileage engine to see what exactly has happened in there. Will post up pictures, nice little job for boxing day perhaps when boredom has struck.
Excellent repair job there. Well done. Nicely documented, thanks for sharing. Maybe you can post up your company details as I'm sure someone here will find it useful in the future.
Hi madfish, we don,t normally turn work away but we'll decline the offer thanks. We did reconstruct the chassis of a chopped up classic ferrari a few years ago, the owner Lord Brocket had cut up his collection and thrown them into a lake as part of an insurance scam. We also manufactured some of the Aluminium body panels from the same car.
