Solo Twin....FINALLY!!!

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I love the video Shaun. I really appreciate having that to add to this restoration. I'd love to know how you re-profiled the part after welding.

I did most of it with a roll lock sanding arbor on a right angle die grinder. A little was done with a stationary 6" belt sander and the intricate parts are with a foredom.
 
Your re-shaping work was spectacular! It looks as though it were machined! There are NO waves, divots, etc.

I use some techniques I learned from repairing or cutting on tube race cars. Once you get close to the original surface you use roll lock sanding disks and keep it pressed flat and hard against the tube. Ensuring that you don't grind a divot in and that the surface is flat. The sanding disk will naturally pick on the high spot.
 
thats a very very nice restauration! The welding job on the one hand, the very positive way you handle and fix the discovered issues on the other hand,
lots of inspiration! Congratulations how you build such a nice saw in the end!

One question, I recently fixed a broken case with glass fiber and epoxy, and kept minor cracks in a sprocket
cover that might have been there for 40 year not affecting the performance...

For the cover, why did you select welding over a better job using fiber reinforced epoxy? Because you just
had a colleague with an amazing skillset? Because in terms of stability, the missing corner would not have to be
very resistant to mechanical stress...

and finally, how much original paint has to be sacrificed in case of welding? How big
would be the area that would burn away or change color? Sth. like 3 inch or more?

very nice, thanks a lot for showing all those details!
 
I have. I apply it with a razor blade, at Mike's suggestion, and scrape filler over the hole in every direction. I guess it's viscous enough that it doesn't want to go in those tiniest holes and displace the air.
That looks great Shawn does good work on everything he puts his hand to.

Brad, have to tried pushing the filler in the pits with your finger?

Have you guys tried something like a toothpick?
Granted the hole has to be large enough for it to fit into.
Or something like a needle or small wire, with the tip a bit flattened.
Just work it almost like you're trying to scratch it out.

In places like that crack in the blasted part, I've used the small wire trick
to work glue into a crack or even a coarse textured surface.
 
Fixed, heading your way soon brad.

3c54ea11b54dc90c7bf3893970815a91.jpg
 
Nice job Srcarr.

I see what you mean about Mag welding. Looks ALOT more forgiving than Aluminum.

So pretty much you use the laywire technique on AC?

Which filler rod and how many did you use?

The grinding and shaping look harder than the welding, but then again, that's what happens when you watch anyone whose good at it.
 

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