Hitchcocks Forum

Hello everyone , I have noticed a large crack on one of the gearbox top mounting tubes on my bullet. Has anyone had this problem before ? It's where one of the 13mm two bolts goes through the casing and attaches to the triangular frame mounting brackets.
The metal looks very brittal , does anyone know what the metal
Is , is it alluminium and if so can it be welded (by specialist of course )
Thanks very much again

Sounds like a 4 speed? Is it completely split or just a chunk missing due to overtightening. Yes it can be welded, but not an easy or cheap job unfortunately.

Hi Midge , it is a 4 speed and there is a chunk about half inch long broken off near one end ( outside end) . Is it alluminium or some poor quality Indian composite. If it can be welded I will get both channels reinforced if possible .
Thanks

The gearbox casing is aluminium and can be welded, but alloy welding is quite specialist and most garages and bike shops can only weld steel.
Firstly are you sure the mount is cracked? I ask because sometimes casting faults can look like cracks especially if there is oil and muck in them. If you are not sure have a good probe with a thin screwdriver and see if you can find solid metal.
If it is obviously cracked then it could be difficult to weld it whilst still fitted to the bike. You will have to remove the clutch and clutch housing to remove the bolts that go through the the mounting, before it can be welded.
If you can't find a welder a new casing shouldn't cost too much, but will take a lot of effort to fit.

Hi John M it is well and truly cracked as the piece just fell off when I was checking it . The gearbox is out of frame now so will try find a specialist welder in morning , as you say it would be a fair bit if work to replace inner workings of gearbox if I get a new shell .
Will keep you informed of progress thank you guys !

I missed your update re the chunk missing, could be worth pricing up a new casing. On the other hand the post 1955 frame does without this mount.

This is a 2002 500 ES , thanks again

Hi VESPA 66------------It's a TiG welder that you'll be wanting for Aluminium..Have a read of this}---- http://en.wikipedia.org/wiki/Gas_tungsten_arc_welding ------------

I would think that would be a tricky weld. New case might be better.

Not sure I'd bother with the welding, second hand Indian and Redditch cases are fairly cheap. I know it's a hassle to swap the innards over but they are very simple.