And Again!!!

[steiner]

Just finished my post trip inspection on the Attak tonight and once again I have broken my W arm. This is the second I have installed. This time I had all gussets and reinforcement done to it. Now it keeps braking at the transfer rod mount.
Thinking or drilling open the side plate where that tube is welded and inserting in some more round pipe inside there and weld it all together. Anyone see an issue with that?​

 

[Winderallday!]

Hi Steiner, just my opinion, I think adding more weld could be creating more stress points and making the pipe area around the welds brittle.
Ideally with this much added weld/gussets the entire arm should have been stress relieved after welding in a heat treat oven.
You could slip a solid round bar or heavy wall pipe inside there to reinforce that area, your call I guess.
If not already done, if you can find a swing arm from an 08+ Apex that would be my next move, much stronger from factory imo.
Cheers

 

[steiner]

Had a welding shop add all the gusset as per a pic from Half Baked. Not sure if they stress relieved the arm. The gussets mimic the 08 and up arms. Maybe even a little bit more than the 08 has.
This has been breaking were they extra welding has not been done. Getting frustrating. I don't beat my machine hard and I don't launch way in the air over approaches and beaver damns.
With my current spring and shock combo I don't bottom out either.

 

[Winderallday!]

The areas adjacent to the welds are getting comprimised and that is why they crack under load. Depending on the welding rod used and the base material of the swing arm, the combination of this and the heat affected zone from the additional welding, this could be changing the mechanical properties sufficient to create weak points.
No expert, but seen enough of this to think this could be credible scenario.

 

[steiner]

Yeah I hear you. I don't fully understand metallurgy but I do understand that while fixing with weld can make things weaker. Just tired of fixing a fix to a part that is supposed to be engineered to take this abuse.

 

[CaptCaper]

Mine 07 broke there and at the top as well so when I took it down it came out in halfs..ha.. amazing it rode o.k. only saw it when servicing ..greasing,etc. I bought a new "beefed" up one from Yami... it lasted 17000 miles.. I had it beefed up way back when Half Baked started doing it..

 

[Redbeard]

Thinking or drilling open the side plate where that tube is welded and inserting in some more round pipe inside there and weld it all together. Anyone see an issue with that?

I think that sounds like a good place to start! You may even consider placing a piece of solid round stock in there, verses pipe?

Take your time and don't get too much weld heat into the piece. Sometimes it's best to weld a little, then walk away for a few minutes before you finish.

Post pics of your fix if you have the opportunity?