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Thread: Welding Ally Barrels ?

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    Retired & Happy Yorick's Avatar
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    Default Welding Ally Barrels ?


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    Mate of mine here has a bit of a problem. Part of the exhaust port has snapped off. Probably one of the many times the exhausts take a hammering when the bike gets dropped.

    I've heard of ally welding before, but is this something that can be repaired? And be able to cope with the exhausts getting smacked against rocks.

    New piston and barrel are about €700






    Last edited by Yorick; 24-09-18 at 11:07.

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    Should Get Out More Tomcat's Avatar
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    Default Re: Welding Ally Barrels ?

    IME welding cast aluminium is rarely successful, especially the high silicon alloys used in pistons and barrels. For one thing you won't get an identical material, for another you'd have to know exactly how to heat treat it to avoid HAZ cracking and get the right grain structure. When I was racing Nortons I used to get through an uncomfortable number of drive side crankcases, they would crack across the main bearing boss. I was working at Rolls-Royce aero engines so I got them welded there, top quality aerospace grade work, but they rarely lasted more than one meeting. So I stooped bothering, at least new ones usually lasted a full season.

    My advice is bite the bullet, get a new barrel and try to avoid bashing the exhaust on rocks. It's not designed for it.
    Last edited by Tomcat; 24-09-18 at 13:01.

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    Should Get Out More Julian_Boolean's Avatar
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    Default Re: Welding Ally Barrels ?

    It can be done, I've had 350 YPVS barrels repaired where the powervalve turns in the barrel with weld, needs to be a really good welder who knows what he's doing for it to last, and never heard of anyone doing it on a modern dirt bike.

    How much is a barrel?

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    Retired & Happy Yorick's Avatar
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    Default Re: Welding Ally Barrels ?

    Quote Originally Posted by Julian_Boolean View Post
    It can be done, I've had 350 YPVS barrels repaired where the powervalve turns in the barrel with weld, needs to be a really good welder who knows what he's doing for it to last, and never heard of anyone doing it on a modern dirt bike.

    How much is a barrel?
    Piston and barrel €700

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    Should Get Out More KungFooBob's Avatar
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    Default Re: Welding Ally Barrels ?

    Quote Originally Posted by Yorick View Post
    Piston and barrel 700
    I bet an aftermarket Athena kit is a 3rd of that.

    What model Husky is it?

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    Should Get Out More Julian_Boolean's Avatar
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    Default Re: Welding Ally Barrels ?

    Quote Originally Posted by Yorick View Post
    Piston and barrel €700
    Should've looked at the pictures and read your post properley.
    Anyway, I'd have it welded and if it went again I'd consider buying a barrel

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    Should Get Out More Big Pete's Avatar
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    Default Re: Welding Ally Barrels ?

    There are high silicon rods specifically for welding ally castings, usually 4043, they are frequently used for repair of blowholes and other defects in raw castings prior to machining. I've dabbled in it, and I've had stuff done in the past that has been fine, mostly crankcase lugs, including engine mounts. Modern casting alloys age harden, and can be artificially aged by heating them and holding to temperature for 3 or 4 hours. The properties change dramatically. There's a very good chance the casting is A356, 4043 rod will work, but won't be as strong as 4008, which is likely to be harder to get in small quantities. 4008 has a better alloy match, and will heat treat the same as a356.


    If it was mine I would build it up with 4043 (4008 if you can get some) and stick the head in the oven for 3 hours at 150C, then machine it back to size. The biggest problem will be getting it clean enough to weld properly, but a decent welder should be able to sort that. Even if it breaks again, he's only down a bit of cash for the welders time. If you got some 4008, you could anneal and re temper the head, followed by artificially aging it again, but you would need an oven good to ~550C (reliably - you're getting close to the melting point), so it's probably more of a PITA than it's worth.

    Before you start, it's worth checking to make sure that it is in fact alluminium, and not magnesium alloy, because that's a whole different ball game.

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    Default Re: Welding Ally Barrels ?

    Quote Originally Posted by Big Pete View Post
    Before you start, it's worth checking to make sure that it is in fact alluminium, and not magnesium alloy, because that's a whole different ball game.
    Heating magnesium to 550C would be interesting.

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    Should Get Out More MrTack's Avatar
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    Default Re: Welding Ally Barrels ?

    Looking at the photo it looks like a collar over the exhaust which is bolted to the head.get him to take it apart and see because it looks as if it just needs a new collar.

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    Default Re: Welding Ally Barrels ?

    +1 it does look like a shadow on the top edge rather than a crack.

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    Default Re: Welding Ally Barrels ?

    The broken part is a bolt on exhaust flange onto the barrel.

    Sadly you cant buy them separately - they're not listed - however there's plenty of worn out barrels around that people cant be bothered to get replated or the bike's seized that may well have an intact flange.

    Ask on the KTM forum if anyones got one or try a few MX breakers.

    I know its a Husky but if its a recent on they are the same engine.

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    Default Re: Welding Ally Barrels ?

    Cool. Now I've looked closer, I can see that it's a separate part. Bet he could get one made

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    Default Re: Welding Ally Barrels ?

    use till engine goes boom


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    Should Get Out More ZRX61's Avatar
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    Default Re: Welding Ally Barrels ?

    Unbolt the flange, vapor blasting would have it clean enough for welding & weld the bugger up... or just find another flange as mentioned.

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