Hit Rock, new A-arms here, bulkhead cracked...

[schroedermn]

My left side A-arms were bent back 2" after hitting a rock last Feb.

I ordered my new A-arms, took the old ones off, and the lower A-ARM back bolt hole in the bulk-head is cracked 1/2".

So, do I just replace the A-ARMS and keep an eye on it, once reassembled you can't see the crack?? (Buyers of used Rx-1's beware of this problem could be hidden on a sled your buying).

OR should I order up a new left bulkhead for $275.00.

Have any of you done this? I know it's possible I'm looking for one of you who has actually removed and reassembled there bulkhead with success. Please list any problems you encountered in R&R??

I've seen other posts where riders have bent there A-arms, I can't believe that the bulk head was not damaged as a result. Problem is that someone could just reassemble the thing and cross their fingers hoping the cracks don't get bigger over time.

Thanks.

 

[LazyBastard]

For $275 I'd replace the bulkhead. If it breaks the rest of the way, you'll still be replacing it, PLUS you'll be doing the A-arms again, steering linkage, maybe shock, maybe some other stuff. Also think of it from a SAFETY standpoint. If it flies apart when you're pulling 110 down a lake, could get nasty.

 

[SRX74EVER]

bulkhead ?

Definitely replace the bulkhead !

 

[spray25]

Could it be welded while still in th sled?

 

[viper2002]

$275 seems like a cheap fix for a $9000 sled when new??

 

[schroedermn]

RX-1 status

Well, tonight I'm going to drink a beer and look at the bulkhead crack again. I'm going to see if the motivation to spend another $300.00 come to me before opening another beer and forgeting about looking at the RX01 for a couple months.... I know I can get the old one off, but getting the new one on again sounds like it may be beyond my riveting skills...

 

[Buckeye]

I agree. I think it's the work of doing it more than the $300 to replace it.

 

[stinx]

Happened on my warrior with less than 1000 miles on it. I replaced all the broken parts. Sled is good as new rides perfect. Bite the bullet and by the new parts.

 

[JDKRXW]

Stinx; how many hours to do the job?

I'd be really tempted to weld it (.... well not me, I'd find an expert with an aluminium gun )

 

[BOUNTYHUNTER]

For $275 I'd replace the bulkhead. If it breaks the rest of the way, you'll still be replacing it, PLUS you'll be doing the A-arms again, steering linkage, maybe shock, maybe some other stuff. Also think of it from a SAFETY standpoint. If it flies apart when you're pulling 110 down a lake, could get nasty.

Very sound advice from LB, you won't be sorry. I wish I had a scanner I could show you the steps to do it. As I took lots of pics when I changed mine. Pick up lots of jobber drill bits as you are going to have to drill out lots of rivets, not worth sharpening as it will take to long.

That was a 2- 1/ 2 day job to change the complete bulkhead assembly on mine[04-Warrior]

Mind you if you dredge it and drill out both ends of the crack, then tig weld it, it could hold for ever or till you wack something else. Hows your welding? for the money go with a new one! as its worry free.

 

[schroedermn]

I took it apart last night, almost, bulkhead is stuck

I drilled out he rivets, removed all bolts, took out engine mount bolt, and the bulk head is stuck in place.

1. Can you remove left half of the bulkhead without removing the right half? The support thing that holds the two halfs together has bolts that stick out and stop my efforts to pull the bulkhead apart!?!?!?

2. For re-assembly will a standard rivet gun from Home Depot work?

So, I'm stuck until I figure out how to proceed.....

 

[spray25]

You are descriding the Delta frame. You have to remove it at least partially. That means the seat, tank, and steering linkage has to come out.

You will kill yourself trying to do structeral rivets with a hand rivet gun. Go get an air gun. Also MAKE SURE you are using structeral rivets!!!

 

[schroedermn]

Delta frame?

The delta frame? I'm talking about the front of the sled, it's almost out and the only thing holding the front left bulkhead assembly on is the engine mount and the piece that goes between the two halfs that make up the front bulkhead. Thanks anyways. Anyone else who has actually had there sled apart?

 

[spray25]

Actually I have one apart right now in my garage. I was trying to help you out. If you don't want help, fine keep being a jerk.

The delta frame (99% sure that is what they call it) holds the two bulk heads together in the front. If you are looking at 4 studs that are protruding through the bulk heads (two on each side) and that is what is holding you up then that is the top of the delta frame.

I seriously doubt the bilk heads can be changed without removing that frame. If it can be done with it in place it will at least be VERY difficult.

However, this is only coming from a person who just did it.

 

[spray25]

Just looked in the service manual. They call it a "Frame Cross Member". I guess I added the "Delta" part, but it is considered part of the overall Delta frame setup.