Hi new member here.my boy has a 2002 Honda 919 that he rear ended a car with the crank case was damaged by The frame slider and was completely broken off (please see attached pictures) was wondering best process to fix if possible to fix or should we just sell it and cut our losses he only had liability insurance I can pretty much do any process of welding I was thinking of using Mig or would tig be a much cleaner process. I did weld a crankcase once for a boat motor OMC I used theMig process. Any advice appreciated.

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you can TIG it, if you know what you are doing and have the experience with aluminum.

You can also find a shop that can do it for you.

follow the link....


Calling Wazoo919... let's talk 919 frame sliders - Wrist Twisters

Well I'm a UA certified welder in tig and stick carbon steel and stainless steel. I have not welded much aluminum though. I just updated my certifications but looking closer this is right next to the timing belt gears n they are plastic and will melt with the temps I would need to weld aluminum. This would have to be totally stripped to crankcase.

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Scrap the engine. You can find a complete engine in better condition for cheaper than the cost of material, time, and labor to wield up the case.

I think a member here by the name of Adambaron might still have a complete engine from his wrecked 919: https://www.wristtwisters.com/forums/...ist-68474.html

That looks like a nasty breakout with fairly large fracture area and thin section.
It should still be repairable.
Accuracy of the repair result will be critical given the thin section breakout, re face of mounting lug to frame and not wanting to stress the repair zone by a mismatch of the clamping faces at the mount.
Using the frame as a jig is one way to ensure maximized accuracy.
The engine needs to be apart, so how about stripping it bare, and fitting an "empty" engine to the frame for the repair?
As in torqued upper and lower casing halves plus head.

Or go Pvester's suggested route.

UH OH !!!!
Another thought.
The bike rear ended a car.
The breakout is suggestive of rearward compressive forcing and/or forward inertial forcing.
Classic slider induced damage tends to shear off the tang laterally.
At least in terms of the broken left sides I've seen pictures of on this website.
The right side engine block is different at the tang, re being near the void for the cam chain.
The frame needs to be checked, head stock, backbone engine hangers in particular.
Step 1 should be to mock up the breakout bit and look for whatever degree of misalignment there is between the hole in tang and frame mount.