Broken Exhaust Bracket

[krolik]

The right side exhaust bracket broke on my '03 M800 Dark. Ducati Performance high might, Remus cans. Anybody know where I can get another one or have one fabricated?

[ducpainter]

No one has a tig welder in your neck of the woods?

[krolik]

Already welded it once. It broke again.

[stopintime]

Already welded it once. It broke again.

...as did mine   

~impossible to find.

[ducpainter]

Already welded it once. It broke again.

Find a  better weldor.

[Ddan]

Find a  better weldor.

Or figure out why there's so much stress on the bracket

[krolik]

The 2 upper tabs (one that is now broken) are what the bracket mounts to the frame, also is the seat lock support.

[Howie]

If the weld broke it was a bad weld.  If it broke next to the weld it is a stress or vibration problem.

[rule62]

With a piece of cardboard to make a template, a band saw to cut, and a drill to make holes... Seems like it'd be a pretty easy piece to make out of a spare piece of metal.

[booger]

If the weld broke it was a bad weld.  If it broke next to the weld it is a stress or vibration problem.

That's aluminum and if I'm not mistaken stressed parts should be annealed after welding to preserve fatigue life & strength. Like heat treated. Repaired aluminum welds are particularly susceptible. You can room temp anneal them but it takes a few years. I had an alu Santa Cruz hardtail mtn bike frame repaired by a dude in the forests of Vermont. Frank The Welder is his name. He did a great job. Can't even tell he replaced a section. I asked him does this need heat treatment, he said yes but since I've had it two years hanging in the shop (I forgot I sent it to him) it's probably OK to ride. Bad welds do exist though, and bad welding rod and substrate combinations exist also. Many factors in getting a good weld, voltage, rod, shielding gas, shielding gas ratios, etc. Can't just weld it up it requires a contemplation period beforehand. Which for a part like that, probably wasn't performed.

Just get a new piece of eighth inch aluminum plate, take your old piece and flatten it in a vise, temp glue the two flat pieces with something, trace it out on the new aluminum plate, cut that out & make the necessary holes. Mark the bend lines. Take it back to the vise, heat it up a little with a Bernzomatic at the bend lines & bend it to approximate the original. Fit any rubber bushings or grommets from the old piece. Hit it with rattlecan.

If you don't want to do this any machine shop or welding shop can make it in an hour. But it will cost you.

[cencalal]

Or make it out of thinner mild steel and forget the heat treating.  Aluminum is easier to bend, but if you go too far it can't be re-bent if expected to last. 

[krolik]

Found a shop to make me one out of steel.

[koko64]