R1200GSA - Welding on frame question

Discussion in 'GS Boxers' started by Homer GSA, Jul 11, 2020.

  1. Homer GSA

    Homer GSA R1200GSA 2008

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    Howdy

    I want to weld a tab onto the steel lower engine frame bracket but am worried about frying the electrics on the poor thing.

    Have welded on heaps of machinery first disconnecting both battery cables but something tells me I am about to do a Charlie Boorman in Kazakhstan.

    Thoughts from the knowledge base.....

    Cheers
    Homer
    #1
  2. Homer GSA01

    Homer GSA01 n00b

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    Here’s the spot..... Adjustments.jpg
    #2
  3. falcofred

    falcofred aka Beer Scout Supporter

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    Is gas/acetylene welding an optinon?
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  4. Fubars

    Fubars What would Scoobydo?

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    I disconnect the ECU, and anything else with wires just to be safe. Use a welding blanket (nomex) to keep spatter off the rest of the bike. Aluminum foil works in layers and it'll bend/fold over any surface. Kinda close to the injection system--drain and remove those and the fuel tank as well. You gonna use MIG?
    #4
  5. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    The ECU is hard to get to on the Hexhead. But, if you disconnect both sides of the battery and isolate them, then ground very close to the weld spot, you should be fine.
    #5
  6. PerazziMx14

    PerazziMx14 Been here awhile

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    Yes disconnect the battery and I'd suggest TIG welding the tab on. No need dragging granddads old A/C stick machine out of the shed and chucking up a 5/23 rod. TIG is clean with no spatter.
    #6
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  7. Homer GSA01

    Homer GSA01 n00b

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    Thanks. Sorry should have mentioned I only have MIG....
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  8. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    MIG will be fine.
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  9. mtncrawler

    mtncrawler Long timer Supporter

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    Sounds like you have plenty of experience welding, but I'd do all you can to mock up the joint (similar or same materials, thicknesses, fit up, prep..etc) on some like materials off the bike first and run a test weld (settings, wire type...etc). Doesn't look like an area you'd want to make any mistakes on. I've done this several times when I can't afford "rework" - even replicating weld position so I limited any surprises.
    Sorry if I'm preaching to the choir (probably all stuff you know) - just thought I'd bring it up. :beer
    #9
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  10. wellcraft

    wellcraft Been here awhile

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    I'm curious...what is the purpose of the tab you want to weld onto the frame?
    #10
  11. snofrog

    snofrog Long timer

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    As a welder that has welded on hundreds of bikes, cars,trucks and mowers. I have never disconnected anything before welding on a vehicle and haven't personally experienced any of the wives tales I have heard of. FWIW
    #11
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  12. larryboy

    larryboy Stable genius.

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    Same here, it doesn't matter.
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  13. Homer GSA01

    Homer GSA01 n00b

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    Well now that you ask.....

    On another thread I have been recording the nightmare that is my total knee replacement and when I am on the GS the angle of my knee is about 2deg off the maximum 125deg of angle i can get.

    So I am looking at making some highway pegs that don’t make me look like I should be wearing a sleeveless leather vest with tassels on it, a Matt black open face helmet and a crazy clown face covering....

    I reckon I can get a couple on each side down in that area. One option is to mount it off a tab on that lower frame piece triangulated up to the crash bar. But removable and unobtrusive.

    Cheers
    #13
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  14. Paladin53

    Paladin53 Been here awhile Supporter

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    As snofrog and larryboy said, I never disconnect the battery on the vehicles I've welded on.
    Do the guys in the muffler shop disconnect the battery when welding on a muffler?
    Connect the ground next to the weld.

    That said, I would be more concerned with changing the temper or ductility of the metal on the frame, setting up a stress point or weak spot.
    In the past I've cut apart and re-welded truck frames and welded hitches to frames.
    But no more. My insurance does not allow.

    I built a trailer for my 2015 GSA. I did not weld to any part of the bike but had parts bolted to the bike that I welded on. Did not disconnect anything.
    Bike is not dead yet.
    I also built a welding bed on a 2012 Dodge 3500. Lots of welding on the bed while on the truck.
    Bolted bed to frame.
    #14
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  15. PerazziMx14

    PerazziMx14 Been here awhile

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    Why care what others think? If traditional highway pegs keep you riding to hell with hat other think!

    As a side note is your front tire on backwards?
    #15
  16. snofrog

    snofrog Long timer

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    The frame is already a welded assy . If welding was going to compromise the tube it would have happened at the factory.
    #16
  17. larryboy

    larryboy Stable genius.

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    And we'd be talking about this in the KTM section.

    :hide
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  18. snofrog

    snofrog Long timer

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    But as long as we are talking about welds 1698F8E5-96AF-4E54-8511-530F58C66EA9.jpeg
    #18
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  19. bikermd

    bikermd Been here awhile

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    very nice weld you can weld anything I want anytime.
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  20. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    #20
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