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DucatiMichael
05-24-2015, 12:27 PM
Well, the ZX had developed a small leak. After some searching I found a tiny hole in one of the tubes.

https://lh3.googleusercontent.com/-qylFdFgUEck/VWIHxY0sSFI/AAAAAAAAPxs/Ygee6z2-kMY/s800/upload_-1.jpg

I am not a fan of any of those fixes that require you to pour anything into your cooling system, and most of those are made as a temporary fix anyway so I decided to give aluminum welding a try, mostly because I forgot about the leak and need to have it leak-free for Palmer in 2 days..and radiator shops are already closed for the long weekend.

I picked up a product called Alumiweld

http://www.alumiweld.com/images/rods5.jpg

Before I attempted this on my very expensive radiator I decided to give it a test run on some aluminum cans I had laying around. It went flawlessly so I moved on to the radiator

https://lh3.googleusercontent.com/-mcQu56gGBZo/VWIHohqs3WI/AAAAAAAAPxc/xu1dNwCIANw/s800/upload_-1.jpg

Drained and removed the radiator then used a dremel to clean up the hole area. It needs to be ultra clean bare metal before you begin welding.

Well, they call it welding but really it is brazing. If you have ever brazed copper pipe, it is the same thing.

I used a propane torch that I had lying around to heat up the area. It is important to note that you heat the area, NOT the rod. Once the area is up to temperature you basically rub the rod back and forth and it melts off and bonds with the aluminum.

So, once that was done I had a nice clean brazed patch. I cleaned it up with a dremel and reinstalled.

https://lh3.googleusercontent.com/-Yehp-6faAso/VWIHerF_b4I/AAAAAAAAPxE/WKc8vDNHmL8/s800/upload_-1.jpg

Leak free, and super easy to do...plus is saved a bunch of $ to a radiator shop that would have done the exact same thing.

MFChop
05-24-2015, 01:00 PM
Sweet, glad you found the leak

tropicoz
05-24-2015, 06:16 PM
I love that stuff. When I found out about it a couple years ago I went around the shop just welding all and any aluminum I could find.

DucatiMichael
05-24-2015, 07:31 PM
I love that stuff. When I found out about it a couple years ago I went around the shop just welding all and any aluminum I could find.

Seriously. Now that I know I can weld aluminum I can see all sorts of fun projects in my future.

The Outlaw
05-24-2015, 09:27 PM
Seriously. Now that I know I can weld aluminum I can see all sorts of fun projects in my future.

Remember your own words in this very thread.

ct1200
05-27-2015, 08:15 AM
Will anyone be surprised if Mike actually makes a functional Iron Man suit someday?

Jonny Rocket
05-27-2015, 08:52 AM
Cox Radiator Guard.

http://www.coxracingroup.com/GREEN-Radiator-Guard_80?sc=2&category=2929

weld
05-27-2015, 03:05 PM
Cox Radiator Guard.

http://www.coxracingroup.com/GREEN-Radiator-Guard_80?sc=2&category=2929
Or $25 for the same thing:
http://www.1000rr.net/forums/modifications-upgrades-08-11/91986-how-diy-radiator-guard-under-$25.html

There are also similar ones to the Cox guard from China for ~$30-40.

The Magician
05-27-2015, 04:08 PM
thats blocking a heck of a lot of air... I'd rather deal with the repair!

csmutty
05-27-2015, 09:29 PM
thats blocking a heck of a lot of air... I'd rather deal with the repair!I had a cox on my r6. Never overheated. Flowed air just fine.

I tried that alumaweld on my radiator once Mike and I must have done it wrong because it wouldn't stick. I'll have to experiment with it again.

DucatiMichael
05-28-2015, 07:34 AM
I had a cox on my r6. Never overheated. Flowed air just fine.

I tried that alumaweld on my radiator once Mike and I must have done it wrong because it wouldn't stick. I'll have to experiment with it again.

Surface needs to be chemically clean...meaning absolutely NO residue of any kind. i.e. grind the spot down to bare metal.

After that, the trick is to heat the metal, NOT the rod. The flame from your torch never touches the rod, it is the heat of the original material that melts the rod and forms the bond.

soofle616
05-28-2015, 08:44 AM
After that, the trick is to heat the metal, NOT the rod. The flame from your torch never touches the rod, it is the heat of the original material that melts the rod and forms the bond.

:iws: With any brazing this is the trick. Most people try to heat the metal and the rod or just the rod and the result is a cold fused joint that doesn't hold up to any amount of stress.

Jonny Rocket
05-28-2015, 09:14 AM
thats blocking a heck of a lot of air... I'd rather deal with the repair!

I have run a guard on my last two motorcycles and they cool just as well with them on as off. ;)

csmutty
05-28-2015, 11:10 AM
Surface needs to be chemically clean...meaning absolutely NO residue of any kind. i.e. grind the spot down to bare metal.

After that, the trick is to heat the metal, NOT the rod. The flame from your torch never touches the rod, it is the heat of the original material that melts the rod and forms the bond.

Yeah the guy who welded it for me said I did an awesome job cleaning it. Guess maybe I didn't have it hot enough? I could get the rod to melt but the bead just came off afterwards.

Yamaha
05-28-2015, 11:13 AM
Are you interested in fixing the radiator on my rsv4? I have a rock chip in one of the tubes and there is an ever so slight pin hole in it...its never even left a drip anywhere, its just enough so some coolant seeps out and when its hot, I can smell it

c5quest
05-31-2015, 11:25 PM
Does it work on people? I know a few mouths I'd like to weld shut some day.

DucatiMichael
06-01-2015, 11:45 AM
Are you interested in fixing the radiator on my rsv4? I have a rock chip in one of the tubes and there is an ever so slight pin hole in it...its never even left a drip anywhere, its just enough so some coolant seeps out and when its hot, I can smell it

If you can bring me the radiator and know where the hole is, I can fix it for you.