Broken throttle lever ... repair ?? (NB)

[lenseman]

Hold the washer in place where it is to be finally welded/brazed/silver soldered and nip-clamp one side firmly with the Mole-grips which are held in a engineering vice by their handles.

Make very sure everything is in correct alignment and that the holes of broken lever and repair washer are correctly aligned and tack weld/braze the washer to the lever on the side away from the Mole-grips.

When it has cooled sufficiently unclamp from Mole-grip and inspect for alignment.

If all is OK, re clamp in Mole-grips and place back in the vice so you can tack the opposite side of the repair. When cool, inspect and check alignment is still OK.

Then finally weld/braze the rest of the circumference if that is your requirement.

Don't forget to paint the weld after it is cool.

 

[nigelmercier]

Hold the washer in place where it is to be finally welded/brazed/silver soldered and nip-clamp one side firmly with the Mole-grips ...

... that you want to destroy.

 

[lenseman]

... that you want to destroy.

Mole-grips do not need to be set that tight, you can set the adjusting screw to just nip the work to be held. An engineer like VicS would know that.

You have to be an engineer to know and understand.

 

[nigelmercier]

Mole-grips do not need to be set that tight...

No, but the tips will get excessively hot.

 

[lenseman]

No, but the tips will get excessively hot.

Not if you are a proper engineer.

 

[vyv_cox]

No, but the tips will get excessively hot.

I have an old set of Mole grips that I have used for years to clamp small parts when oxy acetylene welding. They look a bit oxidised but remain perfectly useable. Ideal tool for the job and when using a small tip for sheet metal welding the thermal input is not enough to do much damage to the relatively large piece of metal that is the Mole jaw.

 

[lenseman]

I have an old set of Mole grips that I have used for years to clamp small parts when oxy acetylene welding. They look a bit oxidised but remain perfectly useable. Ideal tool for the job and when using a small tip for sheet metal welding the thermal input is not enough to do much damage to the relatively large piece of metal that is the Mole jaw.

We will slowly convert these non-engineers, slowly, one by one Vyv! It takes time.

 

[oldbilbo]

"Use The Force, Vic! Use The Force...."

​

 

[rogerthebodger]

The picture shows a broken throttle control lever..

The question is how to repair it.

Brazing/silver soldering I can mange I think but the metal is only 1/16" thick so that's not going to last 5 minutes if just butted together.

I was wondering if I can braze a washer over the break. (I can modify what it fits onto to accept the extra thickness)

If so how can I set it up to hold the bits in place. I can weight the small bit drown on a flat refractory surface and I can prop the cranked bit up level but I cant see how to clamp it.

Any ideas ?

Araldite ? J-B Weld ??

I should have put something in the picture so give an idea of scale .... the washer is a 5/16" one

Vic if you are considering making a new one find some one local who can either laser cut of even plasmer cut. You can make a card template and even thicken the part around the hole or have it made from thicker material

With laser/plasmer cutting shape becomes no problem.

 

[VicS]

We will slowly convert these non-engineers, slowly, one by one Vyv! It takes time.

If the repair was to be a weld then using a pair of vice grips would be fine (although I'd probably keep a manky old pair in with the welding gear for such a use.)

However since I am contemplating silver soldering I need to heat the whole joint. That wont be possible if its half clamped in the vice grips.

I am now contemplating tacking the bits together , while held in the vice grips, with the arc welder and then silver soldering. ( if I can deliver enough heat )

Still rather fancy trying JB Weld though. It seems to be very popular in the US for this sort of minor repair. Dont know how readily avaiable it is in the UK. Halfords did stock it one time I believe but not now. Can order it Frost's I suppose. It would be an interesting test of the stuff on something not critical.

 

[nigelmercier]

I have an old set of Mole grips ...

Indeed, an old set. I was just making the point that it could damage them, or in my case, end up welding them to the work piece

 

[hodge911]

mig welder on low setting .
weld the snapped bits back together then file/dremmel the welds to a nice finish then weld your washer al way round and dres welds to suit repared a couple of simmilar things this way

 

[nigelmercier]

Still rather fancy trying JB Weld though...

I've used it. I don't think it is any better than other epoxy products, which I have very little faith in unless the bonded surfaces are large.

 

[footsoldier]

Still rather fancy trying JB Weld though. It seems to be very popular in the US for this sort of minor repair. Dont know how readily avaiable it is in the UK. Halfords did stock it one time I believe but not now. Can order it Frost's I suppose.

Vic

I've used it successfully in a variety of applications.

I buy it off Ebay where there are a number of stockists.

 

[VicS]

Job done.
Cobbled it all together with the arc welder in the end.

Hopefully will now see me out!

.