Rocker Box Install / Casting Failure?
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Cruiser
Joined: Jul 2013
Posts: 186
Likes: 5
From: Hamilton
Rocker Box Install / Casting Failure?
Looking for advice on a casting failure during a rocker box swap.
I swapped out my rocker boxes both top and bottom for powder coating. Pretty straight forward... I thought.
My 2003 Deuce with the 88B motor had the plastic vent assemblies and when purchasing the new gaskets to finish the job, I found out that the plastic assemblies were obsoleted. So, I bought the new metal vent assemblies.
While I was installing the vent assembly on the front cylinder, the left bolt (under the frames down tube" made a "pop" sound when I was threading it down to prepare it for torquing. I didn't think to much of it at the time as I thought I was just the metal of the new assembly settling in.
Well, during the final look over the motor the next morning I was shocked to find this little hole under the head with a small amount of oil that leached from it.
The forward open channel under the head. At the top of the channel / port. I was thinking there might have been oil at the bottom of the hole for the vent assembly bolt and it hydrauliced and popped the casting at the bottom of the hole? It sucks but figured it would be sealed with the threads and loctite on the bolt.
I ran a pick up the void figuring it would hit the bottom of the bolt but found it was an open void?
I'm pretty concerned about this and was hoping someone can tell me what runs up in that area of the head?
Time to by a new head? Tear down this again??
Any thoughts?
Total buzz kill..
Some pictures
I swapped out my rocker boxes both top and bottom for powder coating. Pretty straight forward... I thought.
My 2003 Deuce with the 88B motor had the plastic vent assemblies and when purchasing the new gaskets to finish the job, I found out that the plastic assemblies were obsoleted. So, I bought the new metal vent assemblies.
While I was installing the vent assembly on the front cylinder, the left bolt (under the frames down tube" made a "pop" sound when I was threading it down to prepare it for torquing. I didn't think to much of it at the time as I thought I was just the metal of the new assembly settling in.
Well, during the final look over the motor the next morning I was shocked to find this little hole under the head with a small amount of oil that leached from it.
The forward open channel under the head. At the top of the channel / port. I was thinking there might have been oil at the bottom of the hole for the vent assembly bolt and it hydrauliced and popped the casting at the bottom of the hole? It sucks but figured it would be sealed with the threads and loctite on the bolt.
I ran a pick up the void figuring it would hit the bottom of the bolt but found it was an open void?
I'm pretty concerned about this and was hoping someone can tell me what runs up in that area of the head?
Time to by a new head? Tear down this again??
Any thoughts?
Total buzz kill..
Some pictures
Seasoned HDF Member
Joined: Mar 2012
Posts: 100,455
Likes: 19,811
From: Centennial, CO
I'd have to say if it's leaking oil, there is a casting failure and that head will be coming off. Start looking on eBay for a set of '06 and up heads. They can be found relatively inexpensively. Possibility exists to have that welded up, but it wouldn't be my choice. Pretty rare occurrence, don't know that I've seen it in here before.
Elite HDF Member
Joined: Jul 2008
Posts: 4,762
Likes: 12
From: north jersey
Damn dude. Not sure that there is a way to repair that (or that you would even want to). Swapping the top half looks like the best option. wonder if you'll need to take the motor off the frame for that.
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Cruiser
Joined: Jul 2013
Posts: 186
Likes: 5
From: Hamilton
Thanks for the reply guys.
So, the oil around the area was from during the removal of the boxes that dripped into the dead hole and pushed through the casting when it popped.
I heard back from my motor guy and he looked at a few heads he had in the shelf.
The area below apparently is a non functioning chamber used during the casting process for forming. The material is really thin there. The upper portion of the motor isn't pressurized and the pin hole won't pose a concern as he thinks the loctite and threads of the bolt will seal the area from any oil issues. The bolt is shouldered also.
Worst case cenerio, a dab of aluminum epoxy will be a solid repair.
I'm hopefully going to fire it up today once I wrap up some other stuff Ive updated on the bike.
Ill keep ya posted fingers crossed!
So, the oil around the area was from during the removal of the boxes that dripped into the dead hole and pushed through the casting when it popped.
I heard back from my motor guy and he looked at a few heads he had in the shelf.
The area below apparently is a non functioning chamber used during the casting process for forming. The material is really thin there. The upper portion of the motor isn't pressurized and the pin hole won't pose a concern as he thinks the loctite and threads of the bolt will seal the area from any oil issues. The bolt is shouldered also.
Worst case cenerio, a dab of aluminum epoxy will be a solid repair.
I'm hopefully going to fire it up today once I wrap up some other stuff Ive updated on the bike.
Ill keep ya posted fingers crossed!
Outstanding HDF Member
Joined: May 2013
Posts: 3,427
Likes: 164
From: Home
The cause was an air bubble during the pour. There could be more in there depending how much the original job was rushed.
Loctite & epoxy breaks down from heat. You will be fighting a losing battle over time if you go that route.
Since your bike is a 2003 model, get heads from '99 to '04. '05 heads have beehive springs and '06 to ?? have been redesigned to the point you will be throwing more money at it to get it to work instead of buying the correct ones in the first place.
Loctite & epoxy breaks down from heat. You will be fighting a losing battle over time if you go that route.
Since your bike is a 2003 model, get heads from '99 to '04. '05 heads have beehive springs and '06 to ?? have been redesigned to the point you will be throwing more money at it to get it to work instead of buying the correct ones in the first place.
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