Alternator Bolt Housing broken :(


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redboy
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Alternator Bolt Housing broken :(

Post by redboy » Thu Jan 04, 2018 7:26 am



Hi All - got a nice piece of bling for the bike for Christmas and needed to remove the alternator. The bolt at the top was stuck so I started to drill it out to replace but the housing has sheared off!!
I'm not sure if this could be TIG welded or if I'm going to need to get the engine out and replace the the whole back cover.
Suggestions/cures anything please!!



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virgilmobile
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Re: Alternator Bolt Housing broken :(

Post by virgilmobile » Thu Jan 04, 2018 8:43 am

If the area is accessible and the broken part is not broken through a area that exposes a internal engine part it may be possible.
I'd take several detailed pictures and go to a welder and have them look at it.
If it's done on the bike,you must remove the battery and I'd hope the welder would take all other precautions involved.
On bike welding is not for the casual welder.Welder grounding,spark shielding,fire control methods have to be considered.

redboy
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Re: Alternator Bolt Housing broken :(

Post by redboy » Thu Jan 04, 2018 11:52 am

The piece that has broken does not expose any internal parts or workings - its just the outside of the bolt housing. I'm going to try some metal epoxy resin first - otherwise it looks as if its going to cost me £200 + for a new housing :(

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virgilmobile
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Re: Alternator Bolt Housing broken :(

Post by virgilmobile » Thu Jan 04, 2018 1:48 pm

Personally don't bother with epoxy.It won't handle the heat.It will look good but no strength.Post a few pictures..We may be able to come up with an alternative.

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Erdeniz Umman
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Re: Alternator Bolt Housing broken :(

Post by Erdeniz Umman » Thu Jan 04, 2018 4:47 pm

I would ask for the same thing, add some pictures then we can comment better. There was a similar issue last year, so we can compare it with yours.

fargofour
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Re: Alternator Bolt Housing broken :(

Post by fargofour » Fri Jan 05, 2018 11:49 am

I realize you’re in the UK but how about eBay? I got one for about $40 on eBay. In very good shape. But what ever you do, removing the rear case is a pain. I’m starting next week to put it back together

Good luck

Bud

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Happytrails
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Re: Alternator Bolt Housing broken :(

Post by Happytrails » Fri Jan 05, 2018 4:22 pm

fargofour wrote:
Fri Jan 05, 2018 11:49 am
I realize you’re in the UK but how about eBay? I got one for about $40 on eBay. In very good shape. But what ever you do, removing the rear case is a pain. I’m starting next week to put it back together

Good luck

Bud
Good suggestion! Or maybe google to see if any bike salvage yards are near you.
1991 GL1500 SE Anniversary Edition
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redboy
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Re: Alternator Bolt Housing broken :(

Post by redboy » Wed Jan 10, 2018 10:01 am

Sill waiting for the JB Weld to arrive hoping it will do the trick. I've also sourced someone who's a TIG Welder if it fails!!
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virgilmobile
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Re: Alternator Bolt Housing broken :(

Post by virgilmobile » Wed Jan 10, 2018 10:54 am

If you glue it back on put some tape over it..It might keep you from loosing it on the road when it falls off.
Or just weld it back on.

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curtm
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Re: Alternator Bolt Housing broken :(

Post by curtm » Wed Jan 10, 2018 6:15 pm

My opinion only, Put the 2 other bolts in and ride, keep an eye on it to be sure it is not coming loose or the other 2 bolts coming loose, I'am betting you could ride for a million miles with only 2 bolts, But be sure to keep an eye on it, if it keeps coming loose, then pursue other options, Been a mechanic for 30 yrs, and see this kind of stuff all the time, although i do not pull wrenches any more iam now a maintenance manager at a large facility

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Re: Alternator Bolt Housing broken :(

Post by WingAdmin » Sat Jan 13, 2018 10:52 am

virgilmobile wrote:
Wed Jan 10, 2018 10:54 am
If you glue it back on put some tape over it..It might keep you from loosing it on the road when it falls off.
Or just weld it back on.
I was thinking the same thing. No way J-B Weld is going to hold that thing in place once the bolt is tightened. Bold threads exert an amazing amount of force, and when that force is applied in shear against the J-B Weld...it's going to come off right away.

Might was well skip that process and just get it welded. :)

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RBGERSON
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Re: Alternator Bolt Housing broken :(

Post by RBGERSON » Sat Jan 13, 2018 1:01 pm

There is another thread about aluminum welding/replacement..form a mold melt the stuff in let it cure, drill tap and good to go????

https://www.aluminumrepair.com/
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seelyark1
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Re: Alternator Bolt Housing broken :(

Post by seelyark1 » Wed Jan 17, 2018 11:50 pm

That is an extremely easy TIG weld to repair. Just needs to be prepped right before welding. You are lucky that it is at a place you can get at!
Ride safe, and smart. Asphalt is like #1 grit sandpaper. Dave

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thrasherg
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Re: Alternator Bolt Housing broken :(

Post by thrasherg » Thu Jan 18, 2018 9:50 am

what is to stop you running a drill down the threaded hole and coming out the back (assuming the hole is currently blind), then either thread the drilled section and use a longer bolt or if you cant thread that section use a longer bolt with a nyloc nut on the back? The alternator will still butt up to the remaining part of the casting, so the alternator will be in the correct place and a longer bolt doesnt look like it would interfere with anything and it looks like a nut could sit in the back? No way any epoxy is going to hold the broken off part in place, the minute you tighten the bolt it will break that part off again.

Gary

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redbug
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Re: Alternator Bolt Housing broken :(

Post by redbug » Thu Jan 18, 2018 11:41 am

Not being familiar with these engines is the broken piece to fit on the bracket as in the picture? Is that a add on bracket? Just curious. You keep talking about the case which I understand and it does look like a corner of the case piece, but then I want to keep staring at this bracket. Thank you.
" Ridin on Tulsa Time "

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hugger-4641
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Re: Alternator Bolt Housing broken :(

Post by hugger-4641 » Thu Jan 18, 2018 11:49 am

thrasherg wrote:
Thu Jan 18, 2018 9:50 am
what is to stop you running a drill down the threaded hole and coming out the back (assuming the hole is currently blind), then either thread the drilled section and use a longer bolt or if you cant thread that section use a longer bolt with a nyloc nut on the back? The alternator will still butt up to the remaining part of the casting, so the alternator will be in the correct place and a longer bolt doesnt look like it would interfere with anything and it looks like a nut could sit in the back? No way any epoxy is going to hold the broken off part in place, the minute you tighten the bolt it will break that part off again.

Gary
I am pretty proficient at Tig welding aluminum, and even if I welded this piece back on I would suggest using Gary's method also.

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seelyark1
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Re: Alternator Bolt Housing broken :(

Post by seelyark1 » Thu Jan 18, 2018 10:28 pm

Bevel the piece and put in place, install the bolt in place to assure thread alignment and weld it up. Remove the bolt, let cool, run a tap into it, then reinstall. If your welder is any good at all, it will be better than new.
Ride safe, and smart. Asphalt is like #1 grit sandpaper. Dave

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MikeB
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Re: Alternator Bolt Housing broken :(

Post by MikeB » Thu Jan 18, 2018 11:23 pm

seelyark1 wrote:
Thu Jan 18, 2018 10:28 pm
Bevel the piece and put in place, install the bolt in place to assure thread alignment and weld it up. Remove the bolt, let cool, run a tap into it, then reinstall. If your welder is any good at all, it will be better than new.
Agreed.
MikeB
Tacoma, WA, USA

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hugger-4641
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Re: Alternator Bolt Housing broken :(

Post by hugger-4641 » Fri Jan 19, 2018 6:46 pm

No, it won't be as good as new because that is heat treated aluminum and once you weld it you change the temper and no way to get it back without heat treating the whole piece. BUT, if the welder is good it may hold.



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