Broken engine case at kickstand bolt M696

[WetDuc]

I have never welded cast aluminum.  Are there any tips you could advise?   
I am most inclined, though, to try the chemical weld first.

[ducpainter]

I have never welded cast aluminum.  Are there any tips you could advise?   
I am most inclined, though, to try the chemical weld first.

I'd advise you don't learn on your rider.

If the jbweld repair fails you can go back to the welding route.

Welding aluminum...plate or cast...is somewhat of an art.

I know the theory, but don't have the experience/talent.

[WetDuc]

My rider is the DS.  We will try the chemweld and see how it goes.  Monday is go-day.

[alibaba]

My welder is a super hi tech kind of guy.  Gets classic parts from all over the country to restore with some strange alloys.  He usually takes a piece of the metal and sends it out for analysis.  Then, if he hasnt been there before, a consultation with Miller or one of the welding machine companies will recommend the correct rod and procedure.  Aluminum alloys vary considerably and often crack on cooling.  Preheat and slow cool are usually required.

[Howie]

I hate to go back on my advice, but if Speeddog says weld it then weld it.

[WetDuc]

The 696 is getting its valve adjustment and a proper cleaning.  Freaking thing was slimebag hell.
I will update on what we do.  Right now, I am leaning towards at least just trying the JB.

[NAKID]

Any chance he was turning the bike on the sidestand? I know some people do that. Sometimes you're good, sometimes you end up with a broken case...

[WetDuc]

No, he wasn't turning the bike on the kickstand. 
The 696 has been rubber side up quite a few times, I think the damage occured from those instances of sadness and road rash.

[Raux]

why is he using the kickstand on the track?

[WetDuc]

This isn't a track bike, just a city killer.

[Raux]

This isn't a track bike, just a city killer.

sorry you keep saying "my rider" didn't realize you meant 'customer'

[WetDuc]

Not a customer, just a friend.

I got the HeliCoils and JB and we will give it a go this week.  I will report back on whether or not it works.
Thanks everyone for the help so far.

[krista]

It looks like the sidestand mounting bracket is like from the 916 family SBK. If you can use one from legacy monsters, they use the other two holes...

[schmaltz03]

I have tig welded a cast engine case before and had a really hard time with it. First the cast aluminum soaks in the oil so no matter how clean you think it is it will come out as soon as you arc. so pre heat with a torch and clean with soap to remove oil. Also try looking up a specialized cleaner for this purpose, not sure if it exists but if it does it will save you some head ache.

[Langanobob]

 ...Some folks think three full threads are enough.  I prefer at least the diameter of the bolt, in other words. if it is an 8 mm. bolt, at least 8 mm. depth, which also happens to be the shortest helicoil available.  Time Serts, IMO, are better but come in longer lengths.  

Howie there's some sort of rule of thumb that if you have three threads fully engaged you have the full strength of the fastener and you don't gain any more joint strength by having more threads engaged - but that applies to steel fasteners and steel threads, not cast aluminum threads.

I got the HeliCoils and JB and we will give it a go this week.  I will report back on whether or not it works.
Thanks everyone for the help so far.

Don't mean to sound like a smartass but there's also a rule of thumb that if it's worth doing it's worth doing right.  If the glue fails you are going to have another project on your hands cleaning it all out in order to weld it.   JB Weld has iron powder in it and even a small amount left in the weld area will contaminate your aluminum weld.  Don't know if a possible future resale is in the equation but a glued together engine case is not exactly a selling point. If it were mine I'd just have it welded and be done with it.  

Bob