 cracked header pipe
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Joined: Jan 2008
Posts: 1,170 Likes: 14
Learned Hand
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OP
Learned Hand
Joined: Jan 2008
Posts: 1,170 Likes: 14 |
I was thinking that the speedy was not sounding right. Really poppy. I touched the right side pipe with my boot and it moved. That's bad! Pulled over and found that the header had cracked off from the flange.
Got to taking the pipe off and the frame bracket that the header mounts to falls off. Both welds broken. One weld appeared to have been cracked for a while.
I had only ridden it about 60 miles since coming of its winter cocoon. No idea when the breaks occurred.
It looks like frame rails and header are readily available on ebay. It should be an interesting surgery.
05 speedmaster - 1100cc, 11:1 racing pistons, Carillo rods, thunderbike cams, ported and polished head, 2mm over intake and exhaust valves, Barnett kevlar clutch, scepter pipes, oversize manifolds, 45mm HSR's, TTP stage 4 firestarter
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Re: cracked header pipe
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Joined: Jan 2005
Posts: 4,072 Likes: 80
Loquacious
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Loquacious
Joined: Jan 2005
Posts: 4,072 Likes: 80 |
Dang! That sucks. Good luck on the repair.
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Re: cracked header pipe
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Joined: Jan 2008
Posts: 1,170 Likes: 14
Learned Hand
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OP
Learned Hand
Joined: Jan 2008
Posts: 1,170 Likes: 14 |
got the replacement frame rail in and the replacement header, wrapped, painted and on the bike last night. Decided to swap out the old fire starter for the 1100 version. Thought I was all done, putting the tank back on, then noticed a blue-ish white color out of the corner of my eye. A wickedly corroded negative battery terminal. So on to that instead of reviewing the fire starter.
05 speedmaster - 1100cc, 11:1 racing pistons, Carillo rods, thunderbike cams, ported and polished head, 2mm over intake and exhaust valves, Barnett kevlar clutch, scepter pipes, oversize manifolds, 45mm HSR's, TTP stage 4 firestarter
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Re: cracked header pipe
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Joined: Feb 2008
Posts: 2,671 Likes: 15
Loquacious
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Loquacious
Joined: Feb 2008
Posts: 2,671 Likes: 15 |
Better to find that corrosion in the garage, eh?
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Re: cracked header pipe
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Joined: Jan 2008
Posts: 1,170 Likes: 14
Learned Hand
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OP
Learned Hand
Joined: Jan 2008
Posts: 1,170 Likes: 14 |
I got it all cleaned up and back on the road Saturday. Runs great. Not having an exhaust leak is really nice!
the 1100 fire starter seems to have really smoothed out this bike. The tune is definitely a better match for the configuration of the engine. Starts right up. Handles the big carbs and the cams. Very fun.
And of course, as soon as I get this bike going the rain starts!
I now have a surplus 904 fire starter, if anyone is interested let me know.
05 speedmaster - 1100cc, 11:1 racing pistons, Carillo rods, thunderbike cams, ported and polished head, 2mm over intake and exhaust valves, Barnett kevlar clutch, scepter pipes, oversize manifolds, 45mm HSR's, TTP stage 4 firestarter
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Re: cracked header pipe
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Joined: Feb 2008
Posts: 2,671 Likes: 15
Loquacious
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Loquacious
Joined: Feb 2008
Posts: 2,671 Likes: 15 |
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Re: cracked header pipe
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Joined: Feb 2008
Posts: 2,671 Likes: 15
Loquacious
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Loquacious
Joined: Feb 2008
Posts: 2,671 Likes: 15 |
^ that is supposed to be a "thumbs up"...
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Re: cracked header pipe
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Joined: Jan 2008
Posts: 1,170 Likes: 14
Learned Hand
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OP
Learned Hand
Joined: Jan 2008
Posts: 1,170 Likes: 14 |
thought that I should post about the root of this problem.
Back when I first tore the motor down to build the 904, I noticed a crack in one of the header ears (where it bolts up to the head). That is a cast stainless steel part welded to a double wall stainless tubing.
I took it to a local shop that does very good work. They fixed the ear and noticed another crack and welded that too.
All good for a lot of miles.
It looks like the weldment on the lower frame rail that the header rubber mounts to, failed. It is a sheet metal tab (steel) welded to the tube of frame rail. It appears to have been a cold weld, so has been that way since day one. When it failed it put the load on the previously repaired header and that cracked right thru the repaired area.
Amazing that it didn't fall off entirely while I was riding!
Last edited by mag10; 07/21/2023 8:47 AM.
05 speedmaster - 1100cc, 11:1 racing pistons, Carillo rods, thunderbike cams, ported and polished head, 2mm over intake and exhaust valves, Barnett kevlar clutch, scepter pipes, oversize manifolds, 45mm HSR's, TTP stage 4 firestarter
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Re: cracked header pipe
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Joined: Feb 2007
Posts: 23,186 Likes: 55
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,186 Likes: 55 |
Seems unusual to crack through the repair. It's been my experience when I wend something it cracks next to the repair if it fails again.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: cracked header pipe
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Joined: Jan 2008
Posts: 1,170 Likes: 14
Learned Hand
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OP
Learned Hand
Joined: Jan 2008
Posts: 1,170 Likes: 14 |
I agree, it seemed unusual, but welding on a casting...
it looked like they had puddled along the crack without adding any material.
the ear that was broken had filer added to both sides.
interesting that it took more than 10 years to fail.
05 speedmaster - 1100cc, 11:1 racing pistons, Carillo rods, thunderbike cams, ported and polished head, 2mm over intake and exhaust valves, Barnett kevlar clutch, scepter pipes, oversize manifolds, 45mm HSR's, TTP stage 4 firestarter
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Re: cracked header pipe
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Joined: Feb 2007
Posts: 23,186 Likes: 55
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,186 Likes: 55 |
Maybe iron? Hard to get a good weld on iron.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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