Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Honda Tech

Honda Tech Honda Tech Forum - For Questions specific and of interest to Honda riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 18 May 2006
Registered Users
Veteran HUBBer
Join Date: Aug 2003
Location: Perth
Posts: 258
welding the frame


Stuck in mud hot and bothered i stuck my XR400 on it's stand to try and boot it into life before my own body gave up the ghost, last go and i fall with the stand snapping-what a crap day- rain etc.. anyway got it home and now need to weld the framewhere the stand bolts onto it, if I get an electric welder take off tank, drain carb and take out CDI, is it going to fy anything in the way of electrics etc.. I recall a mate frying his years ago undertaking the same thing and it needed numerous electrical parts. i have a sick bandit and can't afford to mess up the XR too!

any problems?
Reply With Quote
Old 18 May 2006
Registered Users
Veteran HUBBer
Join Date: May 2002
Location: London, UK
Posts: 638
personally, I'd go with taking off the CDI, but wouldn't worry about the fuel tank. on my XRL, I disconnected the battery, but left the CDI connected - no drama
Reply With Quote
Old 19 May 2006
Registered Users
Veteran HUBBer
Join Date: Oct 2005
Location: Norwich,Ontario,Canada
Posts: 788
welding the frame

And drain the carbs too before you start.
You do not want to set your bike on fire which is a definite possibility with feul vapours coming from the breather tubes or spilled gasoline.
In'96 I broke the rear subframe on my airhead R100 while in El Salvador . A road building project work camp had a welder and they were happy to help. I left the tank on the bike and when the welder was finished I looked down and saw a nice little flame at the bottom end of the tank breather hose down by the swingarm. Quickly snuffed it out with no big fire , but a close call.
Disconnect the battery and place the ground clamp as close to the welding area as possible.
Reply With Quote
Old 19 May 2006
Registered Users
Veteran HUBBer
Join Date: Feb 2006
Posts: 1,513
In my view you should disconnect and insulate both battery terminal lead sets.
you are mig welding and not stick welding. they a bit fierce on frame tubes.
tig is also ok, but i prefer mig fro this application. make sure yo well ventilated, and just in case.. do not have the bike between you and your escape route
Reply With Quote
Old 20 May 2006
Contributing Member
Veteran HUBBer
Join Date: Oct 2002
Location: montana usa
Posts: 525
Welding up bikes

just a note on welding. I routinely weld with a wire feed welder on four wheelers that have engines like the 660 yamaha. No problem there. I also have stripped down and prepped for welding eight honda GL1800, these have a aluminum frame so I pull the CDI and unbolt and insulate the major gound and both battery connectors and the wires to the alternator. When in doubt do a little extra teardown and isolation of electrical components. It's also nice to have someone standing by with a fire extingisher or a fabric tarp to smoother the flames. Watch the battery vent tube also, even a small battery sounds like a gun shot when it explodes from a welder spark igniting the fumes in the vent tube.....and how do I know that you might ask?
Reply With Quote
Old 5 Jun 2006
Registered Users
Veteran HUBBer
Join Date: Aug 2003
Location: Perth
Posts: 258

all went fine, I drained the carb and took the cdi out also took off the tank and all is now stronger than before
Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Broken KLR650 frame wallsts Kawasaki 4 16 Nov 2006 14:43
XT600 Tenere 3AJ frame, wheels, swingarm. London, UK JimboC TRAVEL Bikes for Sale / Wanted 5 19 Jun 2006 18:20
frame welding Stephen Yamaha Tech 3 20 Jul 2005 16:42
Cracking Frame type oil tank damandaz Yamaha Tech 4 26 Jan 2004 06:23
R1100GS Broken Sub Frame jota BMW Tech 1 5 Mar 2002 13:21


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

HU DVD Autumn Special!

Take 40% off Road Heroes Part 1 until October 31 only!

Road Heroes features tales of adventure, joy and sheer terror by veteran travellers Peter and Kay Forwood (193 countries two-up on a Harley); Dr. Greg Frazier (5 times RTW); Tiffany Coates (RTW solo female); and Rene Cormier (University of Gravel Roads).

The first in an exciting new series, Road Heroes features tales of adventure, joy and sheer terror by veteran travellers."Inspiring and hilarious!"

"I loved watching this DVD!"

"Lots of amazing stories and even more amazing photographs, it's great fun and very inspirational."

"Wonderful entertainment!"

Check it out at the HU Store! Remember to use Coupon Code 'HEROES' on your order when you checkout.

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 03:36.