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Author Topic: Adding gussets to my subframe  (Read 2082 times)

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Offline alanB

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Adding gussets to my subframe
« on: September 09, 2013, 08:30:06 am »
Been meaning to do this for quite a while, finally got started yesterday.

I cut some gussets from 50x4mm flat bar and filed them into shape





Then I stripped down the subframe and removed it. 





Another thing I like about the bike is how easy it is to work on :thumleft: - compared to my BMW Dakar which was just ridiculous!

I'll be dropping off the subframe and gussets for welding today hopefully.
« Last Edit: September 09, 2013, 08:32:45 am by alanB »
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Offline sidetrack

Re: Adding gussets to my subframe
« Reply #1 on: September 10, 2013, 02:40:38 pm »
Has the subframe cracked yet or just as a precaution ? My battery tray needs welding.
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Offline laurika

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Re: Adding gussets to my subframe
« Reply #2 on: September 10, 2013, 02:50:00 pm »
Yip, i had gussets put into my xt's subframe also..just to make sure...

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Offline alanB

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Re: Adding gussets to my subframe
« Reply #3 on: September 10, 2013, 03:00:19 pm »
Got the subframe back today







The welder told me that the cast "stubs" that stick out at the back were very soft and melted very easily - he said they must be very weak - which probably explains why they break so frequently.

Anyway mine are now properly strengthened!  :thumleft:

Will assemble it all again hopefully tonight.
« Last Edit: September 10, 2013, 03:17:20 pm by alanB »
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Offline alanB

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Re: Adding gussets to my subframe
« Reply #4 on: September 10, 2013, 03:05:36 pm »
Has the subframe cracked yet or just as a precaution ? My battery tray needs welding.

No sign of cracking - just the engineer in me wanting to solve problems before they occur  :biggrin:

My battery tray is fine, so I didn't bother strengthening it because I figured if it hasn't cracked by now, it wont!  The secret is to not rely on that stupid little rubber band thing to hold the battery down.  I use two heavy duty cable ties and really crank the battery down tight so it doesn't bounce up and down hammering away at the welds!  :thumleft:
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Re: Adding gussets to my subframe
« Reply #5 on: September 11, 2013, 07:51:19 pm »
Good job Allen - do you use a rack or anything on that subframe?

Re the battery tray - I can really recommend the the new generation Li ion batteries. I have the Ultrabat U400 in mine and is half the size of the OEM and weight is ridiculously light... you can just stick it in place with double sided tape! I put a single thin cable tie around just for good luck.
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Offline alanB

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Re: Adding gussets to my subframe
« Reply #6 on: September 11, 2013, 08:08:23 pm »
Good job Allen - do you use a rack or anything on that subframe?

Re the battery tray - I can really recommend the the new generation Li ion batteries. I have the Ultrabat U400 in mine and is half the size of the OEM and weight is ridiculously light... you can just stick it in place with double sided tape! I put a single thin cable tie around just for good luck.

Thanks!

No rack, but I'm planning a trip using a prototype bag that will sit on top of the mudguard.  So I thought I would strengthen the subframe first.  Not that I plan on a big load, just heeding the warnings I see on Cafe Husky etc.

Ja if money was infinite I would get a Li battery, but the current MotoBatt Gel battery is relatively new and works fine.

« Last Edit: September 11, 2013, 08:09:38 pm by alanB »
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Offline Gensetter

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Re: Adding gussets to my subframe
« Reply #7 on: September 12, 2013, 02:50:24 pm »
The hardness of the ally will not make the melting point any different, but the thickness plays a role.
Huskeys are really easy to work on.
 

Offline Straatkat

Re: Adding gussets to my subframe
« Reply #8 on: September 16, 2013, 10:59:59 pm »
Way to go Alan, did mine last month too, just to be sure. You are going to have to be a little creative to get the plastic to fit, I cut a slot in mine and works fine. I ride dirt a lot and the rear mudguard bracket was destroyed, I see yours is still intact? Also see a Li battery in my future....but only when the original one dies.
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Offline alanB

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Re: Adding gussets to my subframe
« Reply #9 on: September 17, 2013, 04:23:08 pm »
Quote
I ride dirt a lot and the rear mudguard bracket was destroyed, I see yours is still intact?

Are you talking about the little aluminium frame under the mudguard?

If so, mine broke twice. I eventually designed my own stronger version and had it cut and bent by the local laser cutting company.   :thumleft:

I have the dxf CAD file somewhere if you want it?
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Re: Adding gussets to my subframe
« Reply #10 on: September 17, 2013, 06:21:36 pm »
Ja I also reinforced that frame - is quite weak.
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Offline Straatkat

Re: Adding gussets to my subframe
« Reply #11 on: September 25, 2013, 10:21:09 pm »
Alan,yes that is the one, under the mudguard. I did quite a lot of different mods/repairs so one evening I just made a stainless one from 3mm plate, needed to get the beast going fast. I get terrible withdrawal symptoms when my Husky is out of action! If it breaks  I will get the file from you and have it made, sommer have a few done. Thanks.
By the way, how many TE 610 owners are in Gauteng? Maybe we should organise a small gathering and swop out ideas etc.
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Offline Teapot

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Re: Adding gussets to my subframe
« Reply #12 on: September 25, 2013, 11:02:43 pm »
Do you think its necessary to add them to a 650 Dakar?
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Offline alanB

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Re: Adding gussets to my subframe
« Reply #13 on: September 26, 2013, 07:44:36 am »
Alan,yes that is the one, under the mudguard. I did quite a lot of different mods/repairs so one evening I just made a stainless one from 3mm plate, needed to get the beast going fast. I get terrible withdrawal symptoms when my Husky is out of action! If it breaks  I will get the file from you and have it made, sommer have a few done. Thanks.
By the way, how many TE 610 owners are in Gauteng? Maybe we should organise a small gathering and swop out ideas etc.

Ja we should get together some time, always nice to meet fellow Husky riders and swap recipes  :biggrin:
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Offline alanB

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Re: Adding gussets to my subframe
« Reply #14 on: September 26, 2013, 07:48:21 am »
Do you think its necessary to add them to a 650 Dakar?

Dont think so.  The Dakar has a steel subframe.

Plus the Husky sub frame is basically an enduro frame it was only really designed to carry the weight of the rider and the back mudguard, not much more IMO.
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Offline Teapot

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Re: Adding gussets to my subframe
« Reply #15 on: September 26, 2013, 08:30:25 am »
:thumleft: thanks bud.
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Offline Straatkat

Re: Adding gussets to my subframe
« Reply #16 on: October 02, 2013, 10:14:04 pm »
Alan, I'll mail you sometime then we can plan something, us Husky guys have to network as there are so few of us and we all face the same challenges.
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Offline TK

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Re: Adding gussets to my subframe
« Reply #17 on: October 03, 2013, 07:36:42 pm »
I'm keen on a get together. Alan I'm collecting tmrw.
 

Offline Mzee

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Re: Adding gussets to my subframe
« Reply #18 on: October 04, 2013, 05:16:45 am »
I will not buy a bike I have to do such major work.
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Re: Adding gussets to my subframe
« Reply #19 on: October 04, 2013, 07:13:31 am »
I will not buy a bike I have to do such major work.

Really not that major and is precautionary for luggage use. Your loss is anothers gain.
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