R100 frame repair

[steve hawkins]

Having been unceremoniously bundled off my R100 a couple of weeks ago, I have now been given the go ahead to fix the damage - the insurance has indicated the funds will be sent shortly.  It is not a huge amount of money, as the bike was only worth a grand.  I have a bit of slack, but am hoping to spend the money carefully, to get the most from it - i.e. new exhaust and some basic paint if I can.

The question I have, is do I fix or replace the frame?

The damage, on the face of it, looks quite minor and localised.  The right hand exhaust took the brunt of the collision, as many will know, I was hit from the rear whilst stationary.  This was a low speed collision.  However this has bent and broken the right footrest hanger, where the exhaust and brake pedal mounts.  The right hand exhaust went through the lady's front grill a did for her radiator.  The silencer although dented and scratched is still the right shape and functional although the right hand header has been distorted at the very end where it goes into the silencer.  The subframe looks okay and the bike rides true.  The rear mudguard and all rear lights were done for. as was the seat cowl.

There are two places where the hanger has cracked/broken.  Firstly the hole that you stick a screw driver in, to remove the rear brake light switch, has a crack running through it and the hanger is distorted in this area.  Secondly, on the underside of the hanger it has snapped at its thinnest point where it goes around the frame loop, before being welded to the strut that goes across the frame, underneath the swing arm.

The whole hanger is sitting a bit high, but not more than half a cm.

The questions are:

How much of the bike to I take apart to effect the repair.  The welding will be close to the swing arm bearings.  I am thinking that I should pull the swing arm out completely.

I have contacts (friends of friends) who can weld.  But is this a good time to learn  myself?  I have access to a MIG welder.

Should I consider cutting off the hanger, close to the frame tubes, reshaping it and then welding it back on.

Should I go and get another frame with a V5.......and all the hassle a complete rebuild and of re-registering etc.

Anyone done this sort of work?

Steve

[montmil]

Having been unceremoniously bundled off my R100 a couple of weeks ago, I have now been given the go ahead to fix the damage - the insurance has indicated the funds will be sent shortly.  It is not a huge amount of money, as the bike was only worth a grand.  I have a bit of slack, but am hoping to spend the money carefully, to get the most from it - i.e. new exhaust and some basic paint if I can.

The question I have, is do I fix or replace the frame?

The damage, on the face of it, looks quite minor and localised.  The right hand exhaust took the brunt of the collision, as many will know, I was hit from the rear whilst stationary.  This was a low speed collision.  However this has bent and broken the right footrest hanger, where the exhaust and brake pedal mounts.  The right hand exhaust went through the lady's front grill a did for her radiator.  The silencer although dented and scratched is still the right shape and functional although the right hand header has been distorted at the very end where it goes into the silencer.  The subframe looks okay and the bike rides true.  The rear mudguard and all rear lights were done for. as was the seat cowl.

There are two places where the hanger has cracked/broken.  Firstly the hole that you stick a screw driver in, to remove the rear brake light switch, has a crack running through it and the hanger is distorted in this area.  Secondly, on the underside of the hanger it has snapped at its thinnest point where it goes around the frame loop, before being welded to the strut that goes across the frame, underneath the swing arm.

The whole hanger is sitting a bit high, but not more than half a cm.

The questions are:

How much of the bike to I take apart to effect the repair.  The welding will be close to the swing arm bearings.  I am thinking that I should pull the swing arm out completely.

I have contacts (friends of friends) who can weld.  But is this a good time to learn  myself?  I have access to a MIG welder.

Should I consider cutting off the hanger, close to the frame tubes, reshaping it and then welding it back on.

Should I go and get another frame with a V5.......and all the hassle a complete rebuild and of re-registering etc.

Anyone done this sort of work?

Steve

Tough questions, Steve... especially without us being able to see what's going on with your chassis. Just to get the ball rolling, I'd be inclined to cut off the hanger, reshape, and weld it back on. I do not think this would be a good time to "learn" to weld with the MIG on your bike's frame. Consider those "contacts" you mentioned.

Just my  [smiley=2cents.gif] worth.  Anybody else? Let's get this bike rebuilt!

Monte

[Jon_P]

use the wire feed to fill in the damaged and cracked areas then reshape with a angle grinder with a flapper sanding wheel. that would be the easiest and most likely the one where people wont see the repair made.

take some pixs and lets see what we have to work with.

[steve hawkins]

All,

Good points, made by all.

I think I will remove the swing arm and take the opportunity to check/fettle/regrease the bearings. It will give the welder better access as well.

I will also probably remove the ear and bash it about a bit. It is obviously bowed slightly, as the crack on the top is overlaped slightly. The mount for the rear brake light switch needs bending as the switch was jammed up against the top edge of the ear and had to be forcibly removed.

The missus has gone 'oop north' to visit relatives for a couple of days and taken the camera with her - and she has left the docking port at her work. What it is doing at work I do not know. So pictures are out for a day or four.

I have just ordered a new set of Ikon springs to freshen the Koni's up and the sub frame needs to be removed and repainted. It was all part of the original list of things to do when I bought the bike. I will check and see if the subframe is 'sprung' when I remove it - they are two a penny anyway.

I am holding off the main order from Motorbins/Motorworks as the cheque has not arrived yet. And I will keep a weather eye on ebay to see if anything I need comes up in the meantime.

Cheers

Steve

Steve H (R65 Cafe Racer)