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Thread: Yes I know, overkill...

  1. #1

    Default Yes I know, overkill...

    Lots of folks successfully re-weld their broken pipe tab back on, but I made a new one. I rode my 2012 200 XC broken for about a year, with it wired in place. I'm not sure, but the wired repair might have been as good as OEM. Then last week my son's 2016 250 XC cracked too, so I broke down and fixed them both the same day. Kinda 2 birds with one rock...

    Wired repair, worked pretty good:


    Ground off the old tab:


    Made a cardboard pattern:


    Much thicker material, same thickness as engine mounts:


    Cut and hammered out a new mounting tab:


    Did a practice weld to set argon flow and amps:


    Tacked it in place:


    Weld and paint:


    Ready to run!


    Andrew
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  3. #2
    KTMTalk Member katlegs's Avatar
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    Default Re: Yes I know, overkill...

    Nice job !
    2015 250 XCW
    2016 350 XC-F

  4. #3
    KTMTalk Member kenpowell's Avatar
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    Default Re: Yes I know, overkill...

    Boy, I wish I had a tig machine. I have stick, mig and oxy/acetylene - out of those 3 I would (and have) used the oxy/acetylene for that repair (because I don't have tig!). Andrew, do you think that chrome moly needs to be normalized after tig? (controversial subject in some circles)
    Ken Powell
    2018 KTM 250 XC-W
    2012 KTM 300 XC with YZ SSS cartridges in WP forks - Sold to son-in-law on 31 October 2014 due to injury - still ride it occasionally
    2003 YZ265WR (WR426 trans except YZ250 2nd gear) with 2005 Slavens revalved AOSS forks - backup bike
    2003 KX125 with KDX220 motor & 2006 YZ250F SSS forks - added Rekluse EXP 3.0 designed for YZ125
    1979 Maico 250 Magnum
    Many, many bikes until now...
    1963 Harley 175cc Scat - 1st motorcycle

  5. #4

    Default Re: Yes I know, overkill...

    Nice work!

  6. #5
    KTMTalk Member altaholic's Avatar
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    Default Re: Yes I know, overkill...

    Nice job Andrew! Boy Iíve been down that road on many bikes.

    side note: Iíve read 309 ss filler is pretty good for dissimilar metals I.e. cromo to mild steel. Thatís what I use
    86 500
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  7. #6

    Default Re: Yes I know, overkill...

    From what i been told chromoly should always be tig welded with mild steel , told by guys who build race cars , with full cages , stainless welds will be brittle, for a tab or bracket you may get away with it , but for a structural joint it is a no no to use stainless on chromoly

  8. #7

    Default Re: Yes I know, overkill...

    Quote Originally Posted by Caddyman View Post
    From what i been told chromoly should always be tig welded with mild steel , told by guys who build race cars , with full cages , stainless welds will be brittle, for a tab or bracket you may get away with it , but for a structural joint it is a no no to use stainless on chromoly
    No, MG600. Thats the stuff.

  9. #8

    Default Re: Yes I know, overkill...

    KTM has taken a million years (well not quite) to rectify this problem. At last they have overcome the issue for the 2019 on 2 strokes! Nice fix though Andrew. Bob

  10. #9
    Administrator jeb's Avatar
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    Default Re: Yes I know, overkill...

    Good work, Andrew. When that happened on my 14 a few years ago, I just migged it back in place. Has held ever since. I have a Tig, but am not very good with it.
    John B - jejb@att.net
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  11. #10
    KTMTalk Member Hagwest's Avatar
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    Default Re: Yes I know, overkill...

    Quote Originally Posted by bobktm808 View Post
    KTM has taken a million years (well not quite) to rectify this problem. At last they have overcome the issue for the 2019 on 2 strokes! Nice fix though Andrew. Bob
    +1. Maybe even a billion years. My 2014 did the same thing.
    2019 250 XC
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