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Old 01-29-2012, 03:11 PM   #2467
Beastly Adventurer
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Joined: Sep 2009
Location: SE Denver-ish
Oddometer: 6,960
Originally Posted by Poolside View Post
Put the work clamp near to the weld, sand off some paint to make a good contact.

Maybe repack the bearing?

Do not clamp on anything supported by the triple clamps, the current will flow through the steering head bearings to complete the circuit and cook 'em. Clamp on the frame as close as possible to the steering head.

I'd cut a piece the same size as the one on the frame, champher all edges (3 on the new piece and 3 on the frame) and your buddy can run a horizontal bead around the bottom of the frame piece and on top of the added piece. The bead will lay down in the groove leaving more weld surface area than plug welds.

Edit: I'm too slow. My DR650 frame is mild steel, any scrap metal he has will work.

2004 DR650: 62,605 miles
2013 WR250R

Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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