DOWNLOAD THE GUSSET WELDING THREAD HERE
https://www.forums.trx250r.org/index.php?action=dlattach;topic=4525.0;attach=2426Welding is best done on bare steel. Whether your using hand tools to take off the paint, paint stripper or the most popular way of sand blasting, the paint will hinder the welding process. Some ask if Tig is stronger or better than Mig (wire). When done correctly the end strength is the same. Tig will just look a lot nicer. But a Mig welder set right will give some nice looking welds. Most of us have access to Mig so this is where we will go. We are using a Millermatic 252 with a gas mix 75% argon 25% carbon dioxide. The welder is set at 17.9 volts and wire speed at 276
The swing-arm gusset is the most important reason the gusset kit was created. Center the collar on the swing arm pivot hole washer (the steel washer weld to the frame). It may be necessary to sand/grind weld splatter that has stuck onto this flat surface in frame production. Only tack this collar in place and then check to see if a socket will fit in the swing arm bolt lock-nut without interference from the collar. If the socket can not rotate freely it will only get worse after paint or PC. So if the socket does not turn freely then break a tack and move the collar until you have clearance for the socket.
I know the pic shows a full weld but it needs to be checked before it is welded in solid.
When the socket has clearance weld in the collar from 3 to 9 o'clock
Time to tack in the swing-arm gusset. You may have noticed the small aluminum tabs laying on the swing-arm mount in the first pick. Made some little tabs to hold the swing-arm gusset level so it will be easier to tack the box-in strips. Just remember to take the tabs out before tacking in the box-in strips. These tabs will start shipping with the standard and complete kits
All tacked in place and ready to weld.
Notice the burn color on the frame. If the burn goes much farther than what is pictured here you are probably welding too hot. The discolored steel goes less than 1/2 way across, more like 1/3 of the way across. This is seen in the last 2 pics as there is still 1/4" of frame that has not been discolored. You do not want to weld hot as welding tends to pull on your frame. Too cold and you do not get enough penetration to gusset the area you are working with.