200x frame crack repair

[Grizzlypeg]

I have an 84 200x that had a frame crack repair done by a previous owner. The crack is on the front down tube right where the front motor mount plate bolt passes through. The previous owner welded an ugly, oversided gusset on the front of the tube. I'd like to remove the massive gusset, sleeve the tube with a split tube on the front and rear. The sleeve would cover the crack and be both above and below the bolt pass through. What do you think? Reasonable idea for making the repair cosmetically and sound?

[Grizzlypeg]

Here's a picture of the previous owner's repair that I want to re-do, more neatly.

[RapidRick]

I've got two frames like that that were repaired by someone else. The best fix is to sleeve over the crack/break and mig/tig it in place.

Looks like you've got some cutting and grinding to do

[Grizzlypeg]

Anyone know how the end of the sleeve should be to reduce it as a stress point. Do you taper it into a V at the ends, or fishmouth it to soften the transition and stress?

[MTS]

Is there a Hole in the bottom of that downtube Where it splits off for the engine cradle..? I haven't seen a 200x up close before...Might have an idea.

[Grizzlypeg]

Is there a Hole in the bottom of that downtube Where it splits off for the engine cradle..? I haven't seen a 200x up close before...Might have an idea.

Yes, the tube is open on the bottom. Very interesting possiblities. What are you thinking?

[MTS]

Just seen this again looking for another thread...Anyways...If its open on the bottom...Try Sleaving it from the inside with a Thick walled Pipe or solid slug...If its long enough all you would need is to drill a couple holes in the Frame Above and Below the crack to Plug weld it in...And drill the hole for the mount bolt...was what i was thinking...Little Better looking...and would spread the stress out over a larger area....I think.

[Grizzlypeg]

Just seen this again looking for another thread...Anyways...If its open on the bottom...Try Sleaving it from the inside with a Thick walled Pipe or solid slug...If its long enough all you would need is to drill a couple holes in the Frame Above and Below the crack to Plug weld it in...And drill the hole for the mount bolt...was what i was thinking...Little Better looking...and would spread the stress out over a larger area....I think.

Yeah, good idea. I like it a lot. I just have to get it past the bolt holes, then redrill it for the motor mount bolts. Hopefully there is no snag at that point. It cracked right at the motor mount bolt boss, so that rigidity and of the motor mount plate probably focuses the stress there.