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Makotosun

Cracked lug on main switch

  • Schu
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Cracked lug on main switch was created by Schu

My CT1C was missing the main ignition switch. I found one on eBay cheap but it had a broken mounting lug. Luckily the broken lug was included with the purchase. Today I gave it my best shot at reattaching the broken lug.

I cut out a half round backing plate from a 1.5" diameter steel tube that used to be a yard umbrella pole. It matched the inner radius of the broken switch mount.

I drilled a couple holes thru the backing plate and the switch mount including the broken lug. That way my JB Weld would smush into the holes and act like pegs on each of the pieces.

I transferred the mounting holes from the mounting bracket on to the edge of a wooden plank so that I could fasten the two broken pieces in the proper position as they would be when installed on the mounting bracket.

Then I mixed up my JB Weld (steel reinforced) and spread it over the inside surface of the main switch mount. Then I squished the backing plate into position making sure it oozed thru the predrilled holes to act as pegs when hardened.

Tomorrow I will fill any gaps, sand it smooth and paint it flat black. I will be hesitant to really tighten down the screws for fear that it may stress and crack my repair. So maybe I will simply snug them up with a touch of red loctite and call it good. Wish me luck!

 
Schu

CT1B, CT1C, JT1, JT2, CT2, RT3, DT360A, GT80B, DT100B, DT125B, DT175B, DT175C, DT250B, DT400B, Z50

Someday, you'll own some Yamahas
The following user(s) Liked this Post: alnarv, Sneezles61
06 Mar 2022 11:46 #1

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Replied by Sneezles61 on topic Cracked lug on main switch

I do like epoxy's potential... I've not tried that stuff yer using... I'd be curious how much abuse it'll with stand.. 
And yes... Good Luck!
Sneezles61
Last edit: 06 Mar 2022 13:14 by Sneezles61. Reason: making it a longer reply
06 Mar 2022 13:13 #2

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Replied by MarkT on topic Cracked lug on main switch

Good luck! 

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1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
06 Mar 2022 20:02 #3

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Replied by Schu on topic Cracked lug on main switch

Well it is fixed and back in place.
It is strong like bull! 

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Schu

CT1B, CT1C, JT1, JT2, CT2, RT3, DT360A, GT80B, DT100B, DT125B, DT175B, DT175C, DT250B, DT400B, Z50

Someday, you'll own some Yamahas
12 Mar 2022 19:13 #4

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Replied by MarkT on topic Cracked lug on main switch

Congrats!  Nice job!
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
12 Mar 2022 19:32 #5

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Replied by msavitt on topic Cracked lug on main switch

nice work!

I used JB to plug a hole in my 1976 Honda CVCC gas tank in 1986 and to recently fix a split on the end of a really nice hammer I abused.  The stuff lasts a very long time too!
13 Mar 2022 00:21 #6

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