Since I couldn't find any pics with this mod I decided to throw up what I did. Now for you aluminum welding pros be gentle...this was my first go at welding aluminum on a cheap 140amp welder with an even cheaper ($99) spool gun. At least I managed not to have any burn-through...


Props to Jack Moore for proving the guidance...


This mod was high on my list as I want my son to enjoy this quad for many years and I have no desire to deal with a broken case out in the woods!

 

Not bad.

 

Well...coming from you I'll take that as a huge compliment. Not easy welding materials of significant thickness difference...even tougher on aluminum because you can't dwell...the PC will cover most of it's ugliness!!

 

What material did you use? Does it matter? I wonder how well JB Weld would do? I'll have to post a picture of the mess of a case I have right now. I have a used case and cover on the way to fix this lt80 I just got for $150. I would like to do this to mine to prevent breakage in the future.

 

I went with Jack's suggestion of 1/4" x 1" aluminum...He used to race the little buggers so I was confident in his expertise.


I don't know about JB weld...heard good & bad about the product...never used it personally...I know it's an adhesive...and doesn't form a molecular bond like welding does...if you know the machine is going to be ridden hard/jumped I'd steer towards welding it...but that's just my $0.02 :P

 

Using an epoxy is probably not a good idea. I bet those aluminum brazing rods would work good though. They have some pretty high psi ratings.

 

Idiots.

 

WTF? Uglier then my ex!

 

Im going take old case cut flanges off then cut sections lay on top good case so match curves then weld. Will be stronger(more weld and contact)and look good.

 

What dirtdevil101 did was the best we could come up with when we were racing.
When we did other supporting in multiple places, the casings just broke in different spots.