Minor engine cover damage

[Spitfire151]

So I took off the starter clutch cover on my 1981 KZ440B, it being my first time, I was overly cautious until I got too confident. What I damaged was an opening for a case bolt. Just the crest of the circle snapped off and the bolt can still do in but I've got a little chunk missing. I'm working out of a cold shed so the metal wasn't too forgiving, nor was my ignorance. What kind of epoxy can I use to fix this?

I've heard Loctite Quick Metal would work... thoughts? -Yes 'be more careful next time!'

I just got a jack for the holiday so it will go up on that so I can work on it easier.

 

[AlphaDogChoppers]

The last thing you want is for a chunk of epoxy to fall off of a makeshift repair and fall into your engine.

Try using a slightly longer screw.

Can you post a picture of the damage so that we can make informed suggestions?

 

[Spitfire151]

Here's a pic:

 

[RoadRash]

Did you manage to retain the piece that broke off?

 

[AlphaDogChoppers]

Ah. It's on the outside.
I would be a little concerned about the crack right below where the piece is missing. Other than that, I don't think it even matters whether you fix it or not. If you want to fix it, use JB Weld or epoxy. Drill out the whole after the JB Weld sets.

 

[Spitfire151]

Thanks for all of the help, I'll try the epoxy while searching for a new one. I'm just concerned for the aesthetics, it bugs me!

 

[DreadRock]

Is that a crack in the metal its self or just in the motor coating ?

 

[Spitfire151]

I looked closely, JUST the motor coating, you can't even notice it normally.

 

[AlphaDogChoppers]

I'm just concerned for the aesthetics, it bugs me!

Oh! Fer fuck sake!

http://youtu.be/XY3TfjOeuhM

 

[Spitfire151]

LOL well said!

Mainly, I broke it so it will forever remind me of a failure and if I can fix it without cheating (buying a new one) than I'd rather do that.

 

[Jesse Lee]

As far as I know, cast aluminum can be welded, and I'd assume that's what your cover is. If it's magnesium, that may be a different story. If you're not sure, you can test it in an inconspicuous spot with a drop of distilled white vinegar, magnesium will fizz, aluminum won't.

A welder could fill that missing chunk in a couple minutes. If you can find a small "mom and pop" welding shop, I can't see that they would charge a whole lot for such a minor repair. You could do the cleaning up yourself. A little grinding, filing, sanding, and polishing, it'd be good as new.... If the case is clear coated though, that'd need to be redone or touched up too...

My $.02, take it for what it's worth

 

[neevo]

Just buy another one: http://bit.ly/Vplh2e

 

[johngofast]

I'd just cut that bolt hole back to the end of the chip, reshape it by grinding and sanding so you can't tell and take it as a good opportunity to sand and polish up the whole cover. Get a 1/4" shorter bolt, or hell replace all the cover bolts with allen head...

 

[Spitfire151]

Fixed w/ JB Weld:


The second pic's shadow makes the hole look uneven, the bolt goes in just fine and the head will cover the majority of the discoloration Thanks all!

 

[DreadRock]

Nice work !!!

 

[Spitfire151]

Thank you!