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hole in frame

Discussion in 'XJ Technical Chat' started by ant797, Apr 18, 2016.

  1. ant797

    ant797 Member

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    i noticed a hole in the frame hovering around the neutral safety switch area its the size of the end of my pinky and end and tapers off to a crease about a cm i was wondering if this is purpasely done as a crumple zone or just something i need to get welded
     
  2. Alan63

    Alan63 Active Member

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    Maybe someone notched it to get to the neutral safety switch , get it fixed properly, or the frame will wobble till it fails..... Not good
    Alan
     
  3. Yardawg

    Yardawg Active Member

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    I noticed small holes on my frame in the exact same spot. Guess I need to get that fixed soon too
     
  4. TheCrazyGnat

    TheCrazyGnat Well-Known Member

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    I believe there is a hole in the frame there to facilitate drainage of any liquid that makes is way into the frame, but I'm not entirely sure. I think this was brought up in a previous thread about something else.
     
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  5. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    That is a common area for the XJ frame to rust. A proper repair is to cut out a section of frame tube back past the rusted area(s) and sleeve weld in a new section. If the holes are small (less than 1/4 the diameter of the tubing is the guideline I use)they can be welded or brazed shut after cleaning them back to unrusted steel.
    Alternatively the rust can be cut put, and a scab welded over the effected area. That is an ugly repair, but done correctly it is nearly as strong as a sleeve repair and takes much less time.
     
    Last edited: Apr 19, 2016
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  6. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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  7. mlew

    mlew Well-Known Member

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    There are drain holes in the frame but they are small, about 1/8 ". If you have a pinky size hole something is wrong.
    Post a pic so we can see.
     
  8. TheCrazyGnat

    TheCrazyGnat Well-Known Member

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    Yes,I missed the pinkie size part; unless you have incredibly small fingers, I'd post a pic.
     
  9. Yardawg

    Yardawg Active Member

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    Cool. I guess mine is just a drain hole then
     
  10. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    I don't know about your pinkie, but mine is 1/2" across at the fingertip. That is four times the size of the drain holes.


    Photos please.
     
    Last edited: Apr 19, 2016
  11. ant797

    ant797 Member

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    i guess it was a drain hole that rusted out
     

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  12. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    If the photo is oriented the way I think it is, that isn't a drain hole. The drain holes are on the very bottom of the tubing.

    Take an awl and probe around the edge of the hole. Get a feel for how thin the steel is there.
     
  13. ant797

    ant797 Member

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    the photo is a bit blurry but uou can see where it sort of tapers off to a crease i think it may have been welded before
     
  14. jayrodoh

    jayrodoh YimYam Premium Member

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    I had rust in the same spot. Luckily my bike was torn down so a quick trip to the welder and a couple six packs, he was able to patch it all up. He did find a couple other spots and fixed/sectioned as needed.

    You don't want your bike coming apart there at 65 MPH :eek:
     
  15. Big swede

    Big swede Active Member

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    It was the same with mine, had to cut it and weld in new peaces about 4 inches on each side. It was rust after sitting outside for 10-15 years, probably got filld with water.... Not sure how much it would affect handling if it broke, think the engine should keep it together anyway.
     
  16. saftie

    saftie Well-Known Member Premium Member

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    Not sure if anyone ever wants to find out
     
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  17. mlew

    mlew Well-Known Member

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    That's looks more like a rust hole that a drain. A drain will be directly on the bottom of the frame, that hole looks to be at the 8 o clock position. I also see cracks coming out from the edges.
     
  18. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Think about how a hinge works.
    The engine is not a stressed member, so it contributes very little to overall chassis stiffness.
    The Maxim engines are rubber mounted, which makes things even less secure after a lower cradle failure. Handling will be affected negatively. It won't fall apart right away, but eventually there will be additional failures as the engine mounting points flex and stress-cracks develop. Before that the back end will feel "wiggly." Wiggly is very not good.
     
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