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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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brake pedal, broken case

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  #1  
Old 1 Week Ago
BTD BTD is offline
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Default Cracked case at brake pedal

Hello all,

I am restoring a 84 Ironhead.

Flushed all the fluids, except brake and getting it to turn over.

Now I have to tackle the big problem.... The previous owner layed it down on the brake pedal, which mounted to the case and cracked.

I have the broken part and am thinking of jb welding, or welding it shut. The question is do i weld it back with the bolt for the peg mount, or close it up and mod it to forward controls.

Also contemplating if i need to remove the entire engine or if i can do this on frame.... it would be nice to do a deep clean if i take it off. As you can see its dirty.

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The stud ripped a chunk right out??? Bad news...

Did it trash your sprocket cover as well???

Looking at the slime leaking out, I'd say you got other problems too...
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Last edited by ferretface; 1 Week Ago at 01:35..
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This thing was sitting for 20 years non op. so yes, needs alot of flushing and cleaning. haha
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Needs a weld job, there is a spud missing that the foot peg stud screws into, that area will need to be built up and machined to match and drilled and tapped.

The other option is to replace that case half
https://www.ebay.com/itm/77-84-HARLE...E/183880745614
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Got some good news and some bad news. 1st the Good News. It's a vary rewarding feeling to have restored an Ironhead Sportster. 2nd the Bad News. SERIOUSLY? Sitting 20 years with a hole in the crankcase, slime dripping out of it next to a transmission sprocket with a rust welded chain. And you want to restore it . . . with JB Weld. Start with a total tear down and restore/rebuild the right way. There are NO SHORT CUTS.
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Lots of good discussion and info in this thread.

http://xlforum.net/forums/showthread.php?t=2066945

JB is just not gonna do it. Metal needs to melt.
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Quote:
Originally Posted by BTD View Post
I have the broken part and am thinking of jb welding, or welding it shut.

I have no experience with welding this kind of damage....

But I have lots of experience with JB Weld. (Don't judge me unless you've walked in my shoes.... )

I believe there is very little chance of success using JB Weld to fix this, so I have to agree with ryder rick, 1Scooter, and Tim the Grim...

JB Weld is good for some repairs, but it's not going to cut it for this one. A good, professional welding job is the only way to go if you're not going to replace the broken case.
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Quote:
Originally Posted by BTD View Post
The question is do i weld it back with the bolt for the peg mount, or close it up and mod it to forward controls.


Follow-up regarding this question....

If I was in this situation, I would close it up and install the forward controls, if I could find or fabricate some forward controls that would work well.

On my '82 Sporty, which I bought new in '82, I have wanted forward controls for a long time, but based on what others have said on this forum and other forums, it may be difficult to get forward controls that will work well and hold up.

So I've stuck with the stock mid controls, with forward pegs out front to make it more comfortable to ride long distances.

Last edited by Yellowstone Kelly; 1 Week Ago at 05:53..
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Quote:
Originally Posted by Yellowstone Kelly View Post

So I've stuck with the stock mid controls, with forward pegs out front to make it more comfortable to ride long distances.
Here's a pic of mine, but I strongly encourage you to do whatever makes you happy with your bike...

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A good aluminum welder/machinist guy can do the weld for relatively short money. The challenge will be putting it back together. Taking it apart is easy. When you have the engine apart, you may find things you will want to fix. It can cost a lot, or a little, depending on how lucky you get and how thorough a job you want to do. You can do the engine up nice the first time you have it apart, or you can take it apart again later.
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