Leaky Pipe Fix

[Larry Wiechman]

 The o-rings had worn grooves in the exhaust port counterbore so deep that even new o-rings and a shot of high temp RTV couldn't keep the goo from leaking.
 
The Fix:


Bore out the counterbore and press in a stainless steel sleeve.

[Danger4u2]

Man, nice work.  Did you glass bead blast?

[BDI]

That's awsome great work it's about time someone did something to fix this problem.

[barryadam]

That looks fantastic.  Did you cut the outlet oversize or just press the insert into the worn port?  If so, did you mill the bottom flat as well?

I like the ss bore AND the end flange.

Didja make more while you were at it?  hmmm?   

[Larry Wiechman]

Man, nice work.  Did you glass bead blast?

Thanks!
 
The aftermath of glass bead blasting is real hard to clean up. Always seems to be a little bit of the dust or beads imbedded in the soft aluminum or stuck in a porosity. A very small amount will do a lot of damage. Tapped holes + glass beads = broken bolts. My workload of broken/stripped fastener repairs went through the roof after Friendly Local Dealer got a Snap-On benchtop blaster. OK, rant over.
 
The casting in the picture was cleaned by soda blasting. The process is about the same as glass beads, but the blast media (baking soda) is not reused. Clean up with hot soapy water.

[Larry Wiechman]

That looks fantastic.  Did you cut the outlet oversize or just press the insert into the worn port?  If so, did you mill the bottom flat as well?

I like the ss bore AND the end flange.

Didja make more while you were at it?  hmmm?   

Outlet inside diameter had to be bored to remove the worn material and allow for the sleeve wall thickness. The bottom face got a light clean up cut to remove any damage and make it square with the bore. Heat the outlet area of the casting 250~300 deg. F and freeze the sleeve for an easy .003 press fit.
 
I'll post a CAD drawing later.

[stewart]

thats a outstanding job  off figuring out and fixing a much needed  repair , could you sell the sleeves or do the job for the   members here on the web site   thanks stewart

[kaw rider]

I would buy acouple of those seal sleeve.

[Larry Wiechman]

Here is a cross section view and the dimensions used in my application. Castings with more severe damage would need to be bored larger, within reason, and adjustments made to the sleeve outside diameter to maintain a .002~.003 press fit.
 
 

[maddoggy]

really nice work. did you make the stainless sleeve or was it a part from something else?

[Larry Wiechman]

really nice work. did you make the stainless sleeve or was it a part from something else?

2.5 inch diameter 304 stainless steel bar, lathe and time.

[nickalosi]

Just registered to this site and saw this ,I have been in this biz for 20 years , Very nice work I have been wanting to do this for the last 10 years on my 250's and now my 1996 Danny hamel 5 hundy. I knew someone would beat me to it.
good job

[weymouth399]

very  my ice bike could use this,(93 been around the block a time or 2) are you going to make more already asked i know and what do you think it would cost roughly
 thanks in advance bob

[Swe_K5_89]

It's really nice to see nice work like this. Almost like art.. 

[hughes]

Nice work larry. Thanks for sharing.