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Author Topic: Broken Exhaust Bracket  (Read 2193 times)
krolik
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« on: June 26, 2021, 09:16:05 AM »

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?

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'03 M800 "not so dark" Dark, Remus high pipes, Cycle Cat clipons & frame sliders, CRG lanesplitter mirrors, Sargent seat, tail chop, Nichols flywheel, modified & powdercoated rearsets, 15/44 gearing, 520 chain & sprockets, TPO Beast pod filters, Power Comander III. 72.95 Rear Wheel HP & 54.29 ft-lbs!

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« Reply #1 on: June 26, 2021, 02:44:27 PM »

No one has a tig welder in your neck of the woods?
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krolik
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« Reply #2 on: June 27, 2021, 07:16:06 AM »

Already welded it once. It broke again. Tongue
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'03 M800 "not so dark" Dark, Remus high pipes, Cycle Cat clipons & frame sliders, CRG lanesplitter mirrors, Sargent seat, tail chop, Nichols flywheel, modified & powdercoated rearsets, 15/44 gearing, 520 chain & sprockets, TPO Beast pod filters, Power Comander III. 72.95 Rear Wheel HP & 54.29 ft-lbs!

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« Reply #3 on: June 27, 2021, 09:01:07 AM »

Already welded it once. It broke again. Tongue

...as did mine    bang head

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« Reply #4 on: June 27, 2021, 02:51:14 PM »

Already welded it once. It broke again. Tongue
Find a  better weldor. Grin
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« Reply #5 on: June 29, 2021, 03:30:43 AM »

Find a  better weldor. Grin
Or figure out why there's so much stress on the bracket
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krolik
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« Reply #6 on: June 29, 2021, 06:52:40 PM »

The 2 upper tabs (one that is now broken) are what the bracket mounts to the frame, also is the seat lock support.
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'03 M800 "not so dark" Dark, Remus high pipes, Cycle Cat clipons & frame sliders, CRG lanesplitter mirrors, Sargent seat, tail chop, Nichols flywheel, modified & powdercoated rearsets, 15/44 gearing, 520 chain & sprockets, TPO Beast pod filters, Power Comander III. 72.95 Rear Wheel HP & 54.29 ft-lbs!

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« Reply #7 on: June 29, 2021, 10:18:58 PM »

If the weld broke it was a bad weld.  If it broke next to the weld it is a stress or vibration problem.
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rule62
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« Reply #8 on: June 29, 2021, 11:16:54 PM »

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.
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booger
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« Reply #9 on: July 20, 2021, 08:57:39 AM »

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.

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« Reply #10 on: July 21, 2021, 05:39:07 PM »

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. 
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krolik
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« Reply #11 on: July 26, 2021, 07:44:36 AM »

Found a shop to make me one out of steel. waytogo
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'03 M800 "not so dark" Dark, Remus high pipes, Cycle Cat clipons & frame sliders, CRG lanesplitter mirrors, Sargent seat, tail chop, Nichols flywheel, modified & powdercoated rearsets, 15/44 gearing, 520 chain & sprockets, TPO Beast pod filters, Power Comander III. 72.95 Rear Wheel HP & 54.29 ft-lbs!

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« Reply #12 on: July 26, 2021, 08:59:15 AM »

 waytogo
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