Daily Slideshow: Motorcycle Welding Part 1

Welding is a Science & an Art

Welding metal, in and of itself, is relatively easy to explain.  Most types of welding utilize two pieces of metal to be permanently fused together via a filler and a heat source to melt the filler and the parent metals.  There are a few exceptions to this definition, such as TIG welding and Stir welding.

However, welding is not simple.  It is as much an art as it is a science.  Attempting to weld on your frame without prior planning and practice will more than likely end in disaster for you and/or your motorcycle.  Improper techniques or tools will lead to ugly and unsafe welds that can destroy the frame.  

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Gaining Experience

There are many options available when it comes to purchasing or using welding equipment.  Factors such as metal thickness, tube or sheet metal, and aluminum or steel play a significant part in the technique and tools used for a successful weld.  Successfully finding the right equipment typically requires some experience.    

That experience is key to knowing what you are purchasing and why. A good way to gain the necessary experience is to take a welding course.  A quick google search for welding classes provides countless options ranging from workshops, community college courses, trade schools, and industrial academies.  These courses will often teach the needed skills while allowing the learner to use their equipment.  This will aid in providing experience and preferences, which will often save the welder money in the long run.  Furthermore, certifications obtained as a result of these courses are useful for a side hustle in welding. 

Another option and my favorite of them is to find one of those older guys/gals that have been in the trade for so long that they'll forget more than you'll ever remember.  Knowing those kinds of people is like gold!  Find them, and glean every bit of knowledge from them that you can (whether or not it has to do with welding).  

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TIG Welding (AC/DC Current)

Gas Tungsten Arc Welding (GTAW), or TIG (Tungsten Inert Gas) TIG welding, utilizes a tungsten alloy electrode and a shielding gas to protect the weld from oxygen and water vapor.  TIG welding can weld two components without a filler metal, although, it can be used as a filler metal.  Switching to AC current allows for a cooler weld while removing impurities from materials like aluminum.  

TIG welding is the hardest and most expensive welding setup to learn and purchase.  However, a TIG welder can produce strong precision welds that are ideal for motorcycle frames.  It also provides a higher degree of flexibility for the various requirements a motorcycle frame would present, such as various metals and types of construction. 

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Oxy-Acetylene Welding

Oxy-Acetylene welding is the lest expensive to get started as it uses a 6,000-degree flame fueled by oxygen and acetylene and a filler rod to complete the welds.  Oxy-Acetylene torches are great for heating metal for various reasons such as bending metal, loosening rusted hardware, and for cutting.  As for welding, it is easy to overheat the metal which could lead to holes in the metal or warping.  As such, it has a steep learning curve for mastering. In addition, oxygen and acetylene can be very dangerous.  Both can cause fires or explosions and acetylene is poisonous.  It is generally not ideal for a motorcycle project due to the downsides and other methods providing a better weld. 

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Arc Welding

Arc welding is one of the oldest forms of welding available.  This welding process uses a consumable metal rod as the electrode, and both the rod and the base metal melt to form the weld.  The electrode rod is usually covered in flux, which melts to form a protective gas shield.  However, the flux solidifies and turns into a protective layer of "slag".  The "slag" has to be chipped or ground off to expose the completed weld under it.  Even though Arc welding will usually be the cheapest to purchase and is easier to master than TIG or Oxy-acetylene, it is not ideal for motorcycle projects as other welding processes allow for more precise welding.

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MIG Welding

Metal Inert Gas (MIG) welding, or Gas Metal Arc Welding (GMAW),  uses a thin wire that is the electrode.  The thin wire is fed from a spool in the welder.  The wire requires replacement when consumed.  A shielding gas can come from a pressurized cylinder or a flux core wire (which is cheaper, but as good as the gas shield method).  

MIG welding machines are popular as they are usually less expensive to purchase and easier to learn.  While ideal in auto body fabrication and repair as most metal is steel, it is less favorable in motorcycle repair and fabrication as motorcycles typically use different metals such as stainless steel, aluminum, and alloys.  

That being said, MIG welders have been successfully used to repair less critical items such as exhaust brackets or fender braces.  While a MIG welder could possibly be used on a frame, a TIG welder with gas shielding on both inside and outside the frame is ideal.  

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For help with your maintenance and repair projects, please visit our how-to section in the forum.