Broken Fin ¯\_(ツ)_/¯

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Is it cool (no pun intended) to just ignore this? I don't know how I never noticed this until I went to tape it up to paint but there it is. The bike will be used for spirited riding in the twisties and perhaps some touring but not gonna get hammered at the track. FYI - stock 73 850 Commando
Broken Fin  ¯\_(ツ)_/¯
 
Unfortunately, the missing piece is precisely where the cylinder temperature is the greatest.

If you have the broke off piece, have it welded back.

If you do not have the piece, fab up a replacement. Use a cast iron sheet if possible. If you use a cold rolled steel plate, roughen both sides of the plate by sand blasting or shot peening. The weld should penetrate the thickness of the plate 100%.

An alternative to sand blasting a piece of cold rolled steel is to brush paint the replacement piece with paint mixed with sand to simulate the sand cast texture of the original. This is more than cosmetic..... the texture enhances heat transfer.

If you do neither, the engine will survive the use you intend to give it, but will run a bit hotter on the left side. You might consider jetting to counter this.

Slick
 
texasSlick said:
Unfortunately, the missing piece is precisely where the cylinder temperature is the greatest.

If you have the broke off piece, have it welded back.

If you do not have the piece, fab up a replacement. Use a cast iron sheet if possible. If you use a cold rolled steel plate, roughen both sides of the plate by sand blasting or shot peening. The weld should penetrate the thickness of the plate 100%.

An alternative to sand blasting a piece of cold rolled steel is to brush paint the replacement piece with paint mixed with sand to simulate the sand cast texture of the original. This is more than cosmetic..... the texture enhances heat transfer.

If you do neither, the engine will survive the use you intend to give it, but will run a bit hotter on the left side. You might consider jetting to counter this.

Slick

Thank you for the advice. I was considering simply ignoring it as it's taken me forever to get this far in the project and I'm antsy to be done with it but I've come this far, why half-ass it now? I'll take a trip to the scrapyard and look for a suitable chunk of metal, fab it up and have a friend weld it in.
 
That is 99% just a cosmetic problem, its going to make only a trace of a difference to the temperature.
It will bug you every time you see it though, for sure...

Make sure your friend is quite familiar with welding CAST IRON.

The WHOLE cylinder has to be preheated, to quite hot, or the welded piece will just
crack and fall off when it cools down, or when you lightly bump it.
Make sure your friend is quite familiar with welding CAST IRON.

Did I mention - Make sure your friend is quite familiar with welding CAST IRON.

Fancy logo !! = ¯\_(ツ)_/¯
 
There are alternative rods for welding cast iron which mean you don't need to do the old "preheat\post heat" thing. They are usually high nickel, and will look rather different. The weld is usually nice and smooth. Some rods become very hard and can only be ground, not filed. Talk to the welder or welding supplier.

The technique is different too. Once the edge prep is done, the new section is shaped, positioned and fixtured. Leave any excess sticking out, as is for the time being. In case of movement, you have some spare to shape - also helps some to reduce the risk of cracking.
Some people liked to have a copper heat soak underneath, I never usually bothered, but it can assist controlling penetration.

Only a short bead is laid down each time, maybe a 1\2" - 1cm. The part must then be allowed to cool naturally to no more than hand hot, before the next bead - I would alternate ends. No forced cooling, we used an old fire blanket to prevent draughts and slow down the cooling.
Fortunately, it is the top fin, so access is easy at least. In the old days there were usually plenty of scrap cylinders around to bash a section of fin from, probably not so much these days.

I have done down and dirty, with low carbon steel and a mig welder. The mig allows a very speedy bead to be laid down. On a long run like the example I would maybe try an interrupted arc. A mig bead is usually nice and ductile.
But leave the patch piece as large as possible to try to balance out the heat soak.
Works OK, but low carbon steel tends to look different, even after blasting.

Leave the thing alone after welding until completely cold.
And if you hear a ping or a snap, you got it wrong.
 
I'd be more worried about what the heat of welding would be doing to the barrel than the loss of cooling area. If it were mine I'd let it go and keep an eye out for another barrel for future replacement if it bugs you.

My personal experience with welding cast iron has been mixed. Doing everything I could to weld a large radiator casting such as pre-heating, using a high nickel rod, doing very short beads, cooling very slowly, etc, was met with a ping sound while doing the final cooling under a welding blanket.

I successfully welded a pump handle in similar fashion but due to the small area I controlled the pre-heat and cooling better and it was very successful.

I'm in agreement that it's more cosmetic than critical unless you're pushing it to the edge.
 
Leo Goff at Memphis Motor Werks. Repaired a broken fin on a Mk3 I had years ago, very reasonable cost; IIRC the shipping was very near the repair cost.
 
I know just enough about welding to know others have given you good advice. I can only add that you should turn over the job to a shop having both the equipment and experience to weld cast iron.

One other tidbit of information I have retrieved from my 50 year old archives .... there is a process called "metal spraying" (or vapor deposition?) that bonds well to cast iron. Whether the entire fin can be reconstructed by such a process, I cannot say, but it is worth looking up a shop that does such work. Perhaps someone else can further comment on this process.

Slick
 
I weld them regularly using 56% silver.

The lower melting point means the barrel never is heated to the phase change temp so it does not warp or become brittle.

The rod is expensive but it's worth it when you co not need to re-bore after the process. Jim
 
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