need to vent. more cracks in frame

[trx450jason]

Well last month I tore my bike done to fix the frame. Had 8 cracks and the subframe was completely cracked in half back by the grab bar. So I bought the lonestar gusset kit and had it tig welded in. Now the upper frame rail on the right side is cracked almost completely around the tube. Really sucks that I just spent $450 on the gussets, welding, and powdercoating. Plus I have a race this weekend. I'm taking it to a fabricating shop tomorrow to see if they can grind off the powdercoat just where the crack is and weld a tube over the crack. Any other ideas?

[honda4life72]

picture?

[trx450jason]

heres one

[trx450jason]

Another, I chipped away some off the powdercoat to make sure it wasnt just flex marks in the powdercoat.

[400exrider707]

Very typical spot, and the only real fix I've seen is the tube that wraps around it completely.

Also adding a gusset kit to a frame that has already been broken/cracked isn't nearly as effective as putting one on before it breaks.

[trx450jason]

I figured that but a $800 is out of the question right now.

[jjm400ex]

how much is a new subframe, mine has several cracks, did you replace yours or have it repaired.

Mine cracked in that same spot on both sides within 6 months of a Bare gusset kit. I took a piece of 1" steel tubing about a foot long and split it down the center. I pounded it over the outside of the frame and welded it in place. It has been a year and it is still holding strong.

[hendershot106]

im having the same problem with my frame cracking after gusseting even with the reinforcement tube over top of that weld u are showing in the pics---- it is cracking the the cast portion of the subframe mount in the middle of the curve--

[hendershot106]

the tube u have on the frame was sposed to be overtop of that weld---

[Jersey450R]

gusseting only makes the weak area move down "around" the gusset. you need a welder who knows how much to heat the frame and weld, just enough. seen this all too aften. thats why i'm hesitant to even gusset my frame. pappy seems to be the man of choice ;)

[Sjorge450R]

heres mine. Its the same on the other side. We used a 1" pipe, cut it to length, then sliced it open and then put it over the rail and welded it.

[Sjorge450R]

another. Sorry for blurry pics. Forget to switch to close up mode.

[trx450jason]

Originally posted by hendershot106
the tube u have on the frame was sposed to be overtop of that weld---

I kind of figured this. The welder must have messed up after a friend of mine gave him the frame and the gusset kit with instructions. Oh well I'm going to put a piece of tubbing over it and have it welded up to fix this once and for all.

[bumble bee band]

i had the same cracks on my 06 frame in the same spot ive had it welded twice now. the good news is i start a welding class here shortly so hopefully i learn how to weld my own stuff i have no idea how hard it is to learn but i wanna get good enough to pass the welders exam and get certified. has anyone taken that test and how hard was it?

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