Quarantine killer

[jbjhillbilly]

Garage Journal has some good write ups on welders (I get lost over there sometimes).

[190mech]

Here is part of AC43.13-1B that has approved repairs,paragraph 4-65 and on,also Figure 4-38 and on are a good start..
raanz.org.nz/techproject/FAA%20AC43.13%20b/Chapter%2004.pdf

I would use the split external tube repair so no jigging is needed,since its under the plastic it will be hidden..Need to measure the OD of your tubes and find a tube with a close ID that can be split and laid over the top..Here is a list of 4130 tubing that has OD and ID;
www.aircraftspruce.com/catalog/mepages/4130tubing_un1.php

Those little inverter flux core welders are a good start,the young lady aircraft mechanic I have working with me got a HF rig,the TITANIUM Easy-Flux 125 Amp Welder,it does darn good!Waaay better than their cheaper models..We use TIG welding for all structural repairs,but a decent repair can be done with flux core..

[jbjhillbilly]

This build in this thread dealt with metal in ways I hadn’t even thought of, but really simplified how to fit pieces together much more easily for welding, especially how tydeancustoms made the end cuts to flush up to a round tube -

49ccscoot.proboards.com/thread/20670/honda-ruckus-cn250-swap-customs

It’s a big thread, but the pics are great.

[hippo008]

The issue here is cost. While I can afford to build out a scooter however I want I just can't justify spending $500 when I don't have to. I need to make a decision about my path forward. After some back and forth with the Dio guy I can get a frame for $400. That's a sure fire this will absolutely work solution. Whats tempting me is this welding option. About the same in terms of cost BUT I get to keep some cool tools as a result.

I have to choose.

[Kenho21]

The choice is yours, and yours alone, Mr. Hippo.

I forget about what movie...

[hellish100]

Do you want to learn how to weld or build a kick ass little scoot and ride it? There’s your answer.

[Kenho21]

Mar 23, 2021 7:17:55 GMT -5 hellish100 said:

Do you want to learn how to weld or build a kick ass little scoot and ride it? There’s your answer.

Hippo, I think you should do both. Learn how to weld, then build it and ride it.

[repherence2]

You could "plug" weld those holes. I mean, it wouldn't be a traditional plug weld in the sense. Normally you would place a piece of ceramic/tile backing so the puddle doesn't fall through. However, that's not really an option.

My approach would be to set the wire fed on low so you don't burn through the base metal. Then lay beads around the hole, and proceed in a circle, like a spiral,until you close the hole up. Then grind back to suit. I was taught the the weld in most cases is stronger than the base metal.

If you do that, make sure you have a vent hole somewhere on that cross pipe. Bad things can happen when pipe/tubing is sealed up and gases build up. If it's sealed up, and gases build up, if you intrude on the pipe and introduce spark via grinder, there is potential for an explosion.

[repherence2]

if you are hesitant about welding, if you know how to solder with a soldering iron, you can weld.

my cousin (an iron worker) once told me,

"if you know how to solder with a soldering iron, you can weld. do you know how to write cursive (script) letter "e"? that's all you do; continuously "write" the letter "e" in cursive. watch the Puddle and not the Light and you'll be good."

i forced myself how to weld because i was building a boosted 93 accord in 2005 and i needed to fabricate charge pipes, downpipe, and exhaust. borrowed a neighbor's MIG wire feed. he didn't have the shielding gas setup so i bought a huge spool of flux core wire for that 110v Lincoln. forced myself to learn how to weld. flux core sucks, lots of cleaning/wire brushing, but it does the job. i even fabriacted/welded up 2 driveway sliding gates for my exwife's house. to this day those gates still stand from 2005. no sliding gate fab experience, just given advice on welding by my cousing and given advice by a former shipfitter on how to prep metal (bevel) for welding. ...then i got a job at pearl harbor and seen our welders lay Killer Beads, especially on lifting pad eyes with fillet welds with 3/4"-1" throats, stick welding, no wire feed. they go through pounds of rods to weld up submarine hulls. shipyard welders are pretty impressive, especially the nuclear welders.

[rocketbooster]

Scooterswap shop showed his aluminium prototype cylinder for Honda. He said that in around the year it will be available. So if this build in not main build, maybe is worth to wait for it. From what he is saying it shoud do 15/18hp from stock stroke. Impresive in my opinion.

[hippo008]

Mar 29, 2021 17:01:39 GMT -5 rocketbooster said:

Scooterswap shop showed his aluminium prototype cylinder for Honda. He said that in around the year it will be available. So if this build in not main build, maybe is worth to wait for it. From what he is saying it shoud do 15/18hp from stock stroke. Impresive in my opinion.

I saw that cylinder. Super cool stuff. I bet it will be a lot longer than a year though. My hope is to build this Dio for the summer and sell my Roughhouse for this riding season. However I do still like the Roughhouse, it's just been a huge pain to work on. So maybe I'll keep them both, who knows. I'd like to finish the Dio soon though.

[hippo008]

I decided against the $500 frame. The seller is just too sketchy and I couldn't justify the price when I already have a perfectly good frame that just needs repairs.

So I broke out the grinder today and made progress on the frame. My plan is to cut out the rotten frame member, clean out the rust on the inside of the down tube with some acid and then weld in a brand new cross member. I don't feel comfortable welding something structural though. Fortunately one of my accounts at work owns a welding business. I'm doing all the prep work plus fabricating the new cross member and my buddy from work I'm paying to weld up the frame for me. I'll save quite a bit of money that way.

Here's my progress for today.





Here's what the old crossmember looked like.



Fortunately for me I have an old Jonway Chinese scooter lying around. The frame of the jonway is an almost exact copy of the Dio frame, even uses the same tube sizes for the frame. So I'm going to a little bone transplant from the Jonway frame onto the Dio so long as the metal is good and a similar gauge.

[yambw’s]

Mar 15, 2021 0:29:51 GMT -5 hippo008 said:

In case anybody is interested, how cool are these Dio Bajas?! That awesome colorway, the bars, the lights, the gauges, totally awesome and unique. 




When the roughhouse gets sold I'm looking to bring one of these stateside under the 25 year exemption. 

Such a cool little thing!

[yambw’s]

Apr 17, 2021 14:02:11 GMT -5 hippo008 said:

I decided against the $500 frame. The seller is just too sketchy and I couldn't justify the price when I already have a perfectly good frame that just needs repairs.

So I broke out the grinder today and made progress on the frame. My plan is to cut out the rotten frame member, clean out the rust on the inside of the down tube with some acid and then weld in a brand new cross member. I don't feel comfortable welding something structural though. Fortunately one of my accounts at work owns a welding business. I'm doing all the prep work plus fabricating the new cross member and my buddy from work I'm paying to weld up the frame for me. I'll save quite a bit of money that way.

Here's my progress for today.





Here's what the old crossmember looked like.



Fortunately for me I have an old Jonway Chinese scooter lying around. The frame of the jonway is an almost exact copy of the Dio frame, even uses the same tube sizes for the frame. So I'm going to a little bone transplant from the Jonway frame onto the Dio so long as the metal is good and a similar gauge.

Sweet build

[Kenho21]

Apr 17, 2021 14:02:11 GMT -5 hippo008 said:

I decided against the $500 frame. The seller is just too sketchy and I couldn't justify the price when I already have a perfectly good frame that just needs repairs.

So I broke out the grinder today and made progress on the frame. My plan is to cut out the rotten frame member, clean out the rust on the inside of the down tube with some acid and then weld in a brand new cross member. I don't feel comfortable welding something structural though. Fortunately one of my accounts at work owns a welding business. I'm doing all the prep work plus fabricating the new cross member and my buddy from work I'm paying to weld up the frame for me. I'll save quite a bit of money that way.

Here's my progress for today.





Here's what the old crossmember looked like.



Fortunately for me I have an old Jonway Chinese scooter lying around. The frame of the jonway is an almost exact copy of the Dio frame, even uses the same tube sizes for the frame. So I'm going to a little bone transplant from the Jonway frame onto the Dio so long as the metal is good and a similar gauge.

Hell yeah man! So glad you were able to get a plan together (and sounds like a good one) to keep the build going. It'll only be that much more worth it when you're done.