TRX250r.org

Author Topic: 86 gusset welding pics and tips  (Read 10996 times)

Offline Pumashine

86 gusset welding pics and tips
« on: March 02, 2014, 10:48:13 AM »
Welding 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.
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/

Offline Pumashine

Frame Gussets
« Reply #1 on: March 02, 2014, 01:35:02 PM »
The rear grab bar reinforcement will need to be cut to fit. Each frame is a little different so this is cut over-sized. Also alows for replacement of the grab bar mount if it has been severely damaged. A threaded spacer can be welded to each end to replace the damaged mounts.

After fitting, tack in place

I know not everyone thinks the rear grab bar reinforcement is needed. But here in the pic of the grab bar reinforcement welded in you will see where the previous owner had the rear seat latch mount torn away or severely cracked for some reason then welded back up (bird poop welds).

*Note if you use the grab bar reinforcement your seat latch will no longer be able to used. The 2014 Pumashine seat latch will take care of this problem.

The rear sub-frame gusset is short enough to clear your coolant reservoir. Center it on the tubing usually works good and tack. Check to see coolant reservoir clears on the left side.

The lower sub-frame gusset goes in the center of the tube also. A little may need to be sanded of the apex to clear the weld where the frame tube comes together.

The lower frame rail gusset gets tacked in the center of the frame tubing also.

Lower steering stem gusset.
« Last Edit: October 18, 2014, 02:11:00 PM by Pumashine »
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/

Offline Pumashine

86 Radiator shroud mount
« Reply #2 on: March 02, 2014, 02:02:12 PM »
The 1986 TRX250R was the first year production for our prized hobby. There was a sheet metal part made to mount the upper tab of the shrouds. This part wraps around the frame and uses a nearby threaded hole to mount to. This part never made it to the microfiche. In 1987 the wrap around part was converted to a 6mm threaded tab and was welded onto the frame. This copied through to 88 and 89. Many of these are misplaced in a rebuild or lost through the years. So this one is included with the gusset kit. Not a gusset but a better option than wire ties like I have seen numerous times. Side view of 86 and 87(red)

Other side

The upper part of the tab lines up with the lower part of the CDI mount.You may need to trim the bottom of the CDI mount or top of the shroud mount. I only trimmed 1/16 off and a little weld. OK because it gets welded back up when finished.

You want to adjust the clamp until the 6mm threaded hole in the shroud mount is 2" from the 8mm hole for the fenders. Tack the corners and check you have 2" hole center to center.
« Last Edit: March 02, 2014, 02:14:15 PM by Pumashine »
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/

Offline Pumashine

Shock tower reinforcement
« Reply #3 on: March 02, 2014, 02:41:46 PM »
The shock tower reinforcement was the last addition to the Wrath kit. This part was suggested by member 2r's on trx250r.net. Again the part is made at least 1/8" wider than most frames. It needs to be trimmed to fit.

Then tack as shown in pic.Top, bottom, front, and back.

Then weld it uo where ever the bar meets the frame. Front

Back

 
This completes the gussets that reinforce the 1986 frame.
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/

Offline Pumashine

Frame gussets welded in after tacked into place
« Reply #4 on: March 02, 2014, 02:48:11 PM »
Here are all the frame gussets welded in.
Rear sub-frame

Lower sub-frame

Lower frame rail

Lower steering stem
« Last Edit: October 18, 2014, 02:12:34 PM by Pumashine »
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/

Offline tlr7272

86 gusset welding pics and tips
« Reply #5 on: November 22, 2014, 04:43:02 AM »
I need SERIOUS help on my frame ???? do they mke front motor mount kits mine aere a mangled mess looks like a 3 yr old welded it they cut sparas outta bottom of frame and put a piece of plate steel which might not b that bad it just needs all re welded and I don't know what to do...??? should I just break fown and by an 88-89 frame???? thank u and I just seen the pics and had tgo comment

Offline Pumashine

86 gusset welding pics and tips
« Reply #6 on: November 22, 2014, 09:21:00 AM »
Quote from: tlr7272;46421
I need SERIOUS help on my frame ???? do they mke front motor mount kits mine aere a mangled mess  
Not many places making trx250r frame repair parts. There are lower motor mounts in the gusset kit section and front motor mounts in the dress up section in  http://www.tlr-online.com/trx250r/dress_up
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/

Offline Big_Mike

86 gusset welding pics and tips
« Reply #7 on: November 22, 2014, 12:12:49 PM »
That's awesome Puma!  I love your kit, I had mine professionally welded on my frame by JL Industries - same company who fabricated my swing arm..  I have some awesome pictures of my Puma gussett kit being installed I'd love to post the pics of you don't mind...

Offline Pumashine

86 gusset welding pics and tips
« Reply #8 on: November 22, 2014, 02:47:25 PM »
Quote from: Big_Mike;46435
That's awesome Puma!  I love your kit, I had mine professionally welded on my frame by JL Industries - same company who fabricated my swing arm..  I have some awesome pictures of my Puma gussett kit being installed I'd love to post the pics of you don't mind...
Yes Mike, that would be great. I am getting a frame done this next week using the TIG. I would like any pics you have of the gusset welding operation. Thanks, Tony
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/

Offline Big_Mike

86 gusset welding pics and tips
« Reply #9 on: November 22, 2014, 03:58:26 PM »
Awesome- here we go...  Gussett kit compliments of Puma, welding performed by JL Industries...  I have many more photos but these are all I've got on my phone right now..  I'm am VERY PLEASED!!!





« Last Edit: June 28, 2015, 01:45:04 PM by Pumashine »

Offline Big_Mike

86 gusset welding pics and tips
« Reply #10 on: November 22, 2014, 04:48:36 PM »
;)


Offline Chrismil

86 gusset welding pics and tips
« Reply #11 on: December 28, 2014, 03:09:28 PM »
Is the 1986 TRX250R gusset kit the same as the 1987 TRX250R Kit? Thanks.

Offline Pumashine

86 gusset welding pics and tips
« Reply #12 on: December 28, 2014, 04:10:04 PM »
Quote from: Chrismil;48136
Is the 1986 TRX250R gusset kit the same as the 1987 TRX250R Kit? Thanks.
The front motor mount substructure (cast iron) was replaced by formed sheet metal in 87 to 89. Therefore the 87-89 kits have 4 triangle gussets used to support this area. The 87 swing-arm location gusset has a notch to clear a bracket that was welded in that area. All the other gussets will interchange from year to year. The 86 lower motor mount is supplied in all the kits as it is much easier to replace than the 87-89 mounts that are flat and twisted parallel as you weld them in. The 86 lower motor mount just sets flat on the lower frame rail.

A simple answer is you can put the 86 kit on any year. All gusset kit pics have been updated this year to show exactly what you are getting with the purchase.
Puma 408, Puma 431,  Pilot 412, Puma 431, Mini-tooth 486 Trx450r
89mm  Mini tooth Shearer in frame pipe chromed! Mounted with Cascade QUIET[/