Missed a shift today..

[g5guzzi]

Mine did the same 4 weeks ago. Had a 1/4 inch bolt welded top and bottom
to strengthen it. Not pretty but it works.

Malc

[Chuck in Indiana]

Mine did the same 4 weeks ago. Had a 1/4 inch bolt welded top and bottom
to strengthen it. Not pretty but it works.

Malc

I had a good look at the toe lever end with my 10X glass, and the chrome plating is cracked there, too. It's only a matter of time..
I'll grind the chrome off that end, V it out, and TIG it, too. Looks like bead blast and powder coat will be the final finish. Nobody around here does chrome plating any more. <shrug>
All you people with these shift levers.. don't say we didn't warn you. 

[RinkRat II]

     Aww C'mon Chuck, just whip up a program for that Mazak machining center of yours and make up some Billet ones. They'll sell like hotcakes


        Paul B

[Cal3Me]

chuck ,,,,, I broke 2 of those levers and one of the guys here that owned the bike after me broke a couple levers and after I got the bike back broke another one . That is why you have those welded up spares. Your a metal spinner fashion one up and weld it to the pivot and be done with it ...

[lucky phil]

I had a good look at the toe lever end with my 10X glass, and the chrome plating is cracked there, too. It's only a matter of time..
I'll grind the chrome off that end, V it out, and TIG it, too. Looks like bead blast and powder coat will be the final finish. Nobody around here does chrome plating any more. <shrug>
All you people with these shift levers.. don't say we didn't warn you. 

Decorative Chrome means Hydrogen embrittlement on loaded/stressed steel.

Ciao

[Chuck in Indiana]

Decorative Chrome means Hydrogen embrittlement on loaded/stressed steel.

Ciao

Yeah, unless it's been baked. *Many* years ago, a guy from Texas had a very pretty if a little over done homebuilt biplane at Rockford. Tooled leather seats, chrome plated cabanes, N struts, etc. When I mentioned hydrogen embrittlement, he blew me off. After all, I was just a kid. It didn't end well eventually.

[Chuck in Indiana]

chuck ,,,,, I broke 2 of those levers and one of the guys here that owned the bike after me broke a couple levers and after I got the bike back broke another one . That is why you have those welded up spares. Your a metal spinner fashion one up and weld it to the pivot and be done with it ...

Eeks, Timmy.. I didn't realize they were *that* prone to breakage. I just assumed it was the stress riser down by the pivot. Austin has the cnc tied up for the foreseeable future, though. Hmmm, I could make a billet aluminum one. After all, Guzzis are all about lightness..  What I *won't* do is spend $250.19 for one. 

[Chuck in Indiana]

Closure to this thread. Austin shut down the cnc late Friday, so yesterday I could weld. I've had a very bad experience with TIG welding while a cnc was running..This modern cnc stuff is probably ok, but still. Apparently even if I cough cough *bought*  a new one at $250.19 it's going to break eventually anyway.
So. I made up a piece of steel that fit the inside of the shifter arm tubing pretty well. Welded that to the pivot. Drove the shifter arm on to that stub, welded it to the piece of steel at the pivot, and put a couple of rosette welds on the arm on both sides. There was also a crack at the toe lever, so welded that, too.

Powder coated the whole works flat black because the chrome was toast. It's certainly ugly welding, but all I'm going to say is YOU try welding tubing that is chrome on the outside and rust on the inside with TIG.  It's stuck, at any rate, and I expect it to be a permanent repair.

[RinkRat II]

     This time You get the  "Atta Boy" Chuck, In the big scheme of thing it's a minor repair, however to have the skills and tools to do it is what it's all about.

         PaulB

[Tom]

For the most part, a repair that works and doesn't cost you $250 is the most important thing.     Cosmetics aside, it's proper fix and you can't see it while riding.   

[Muzz]

This should test my mad TIG skilz. Chrome on the outside, rust on the inside.. 

If they are half as good as your ultralight skills I am sure you will do just fine Chuck!

[lucian]

Nice work Chuck , as always,  would love to own a tig someday. Have always gotten by with gas welding thin steel tubing etc .  I have a friend who tig 's aluminum bicycle  frames that are basically not much thicker than a  beer can. I'd be happy to be able to weld stainless exhaust tubing without blowing holes through it. 
Great fun to be able to repair things like this when they happen. Almost as fun as breaking them in the first place.