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Site Sponsors => Pumashine 250R Products => Topic started by: Pumashine on March 02, 2014, 10:48:13 AM
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DOWNLOAD THE GUSSET WELDING THREAD HERE https://www.forums.trx250r.org/index.php?action=dlattach;topic=4525.0;attach=2426
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
(http://i60.tinypic.com/112d6ap.jpg)
(http://i59.tinypic.com/rhtilw.jpg)
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.
(http://i62.tinypic.com/2qlbajt.jpg)
I know the pic shows a full weld but it needs to be checked before it is welded in solid.
(http://i58.tinypic.com/2ptxta8.jpg)
When the socket has clearance weld in the collar from 3 to 9 o'clock
(http://i59.tinypic.com/nbareb.jpg)
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
(http://i62.tinypic.com/3148hue.jpg)
(http://i61.tinypic.com/2ng4m0l.jpg)
All tacked in place and ready to weld.
(http://i60.tinypic.com/t7zsm0.jpg)
(http://i57.tinypic.com/2z9kvth.jpg)
(http://i57.tinypic.com/2r761p3.jpg)
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.
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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
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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
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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...
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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
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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!!!
(http://img.photobucket.com/albums/v472/bigmike11554/brandnewPC1.jpg) (http://smg.photobucket.com/user/bigmike11554/media/brandnewPC1.jpg.html)
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;)
(http://img.photobucket.com/albums/v472/bigmike11554/Mobile%20Uploads/2014-07/B879001F-9111-435C-A5FF-ABCB78FF3C83.jpg) (http://smg.photobucket.com/user/bigmike11554/media/Mobile%20Uploads/2014-07/B879001F-9111-435C-A5FF-ABCB78FF3C83.jpg.html)
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Is the 1986 TRX250R gusset kit the same as the 1987 TRX250R Kit? Thanks.
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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.
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@Pumashine - looks like these pics are down from Tiny pic - not sure if it was the site migration or just Tinypic issue (the referenced url's don't go through either on their site). Would you mind uploading the pics again (or sending to me and I can do it).
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Compiled the instructions into a PDF for those of you wanting to use during your install. Feel free to give feedback!
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Pumashine...Any chance of you making a 88-89 rear motor mount so that it could be welded into an 86 frame?...That way making it easy to run a 88-89 swingarm which seem to be more readily available through the after market
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Compiled the instructions into a PDF for those of you wanting to use during your install. Feel free to give feedback!
cool. ive been waiting on something like this to take to my welder to get a frame done up. thx!