Bolt-on hard-tail Problem - The Jockey Journal Board

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Old 09-01-2014, 01:42 AM   #1
Swearfinger
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Exclamation Bolt-on hard-tail Problem

Maybe I'm worrying too much but as you can see on this '74 Sporty, the holes for the exhaust support mount is drilled way off center. The Bird hard-tail is supposed to utilize these holes. I think I'm screwed. I think I may need to go the weld-on route, leaving me with a brand new useless bolt-on. My two concerns are;

1- That bracket will break under the stresses
2- The hard-tail wont fit right, or be tweaked

Do I need to get that filled in with welding and punch a new hole?

Any experienced recommendations are greatly appreciated. Thanks in advance!!!

The link below is to my pic album but it appears not to be working, it's in my profile, I will try to embed into this post ASAP.


Last edited by Swearfinger; 09-01-2014 at 01:51 AM. Reason: Picture not working
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Old 09-01-2014, 01:52 AM   #2
VonWegener
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Default Re: Bolt-on hard-tail Problem

It all depends on when in the assembly of the frame at the factory those holes were drilled. They maybe be in the right location but the bracket got on the frame wrong.
You need to compare the hole locations from right and left versus a known point on the front of the frame.
If the hole location is correct I would not worry about the wall thickness as long grade 5 bolts are used and tightenend to spec.
If the bolt holes are off maybe you can offset the holes in the hardtail?
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Old 09-01-2014, 01:53 AM   #3
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Old 09-01-2014, 01:55 AM   #4
C1340
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Default Re: Bolt-on hard-tail Problem

I would not use it. Probably would fill it up and drill a new hole.
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Old 09-01-2014, 01:56 AM   #5
Swearfinger
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Default Re: Bolt-on hard-tail Problem

Thanks, VonWegener. My hope is that they are in the correct spot and that they wont crack under the stress of that hard tail. Aside from two bolts that mount to the top of the frame, those below are what get and keep the job done.
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Old 09-01-2014, 01:59 AM   #6
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Default Re: Bolt-on hard-tail Problem

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Originally Posted by C1340 View Post
I would not use it. Probably would fill it up and drill a new hole.
That seems like the safest option. Do you have a recommendation as to how to go about that? Grind that thin wall away and have a buddy weld across it or is it possible to fill the hole some way?
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Old 09-01-2014, 09:33 AM   #7
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Default Re: Bolt-on hard-tail Problem

I'd cut or grind away the hole then weld it in. That's a quick easy fix.
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Old 09-01-2014, 09:39 AM   #8
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Default Re: Bolt-on hard-tail Problem

If it was me I'd run it. Bolt it up make sure everything is straight and square, use good hardware, then put a weld on the bottom side to the frame. Make it easy to grind off if needed. Easy, simple, effective.
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Old 09-01-2014, 01:16 PM   #9
Swearfinger
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Default Re: Bolt-on hard-tail Problem

Thanks for the input everybody. I measured it up and the holes are aligned. I guess they didn't weld frames using jigs back in the day. My crude-style measuring shows that the offset-holes are square to the frame. Those "exhaust mounts" were welded differently from each other. One is welded to the frame farther forward, so when they punched those holes, the one is offset. I think the best option is to do a hybrid of all your suggestions. High quality grade-5 hardware, bolt the tail on and weld it along the bottom where it meets the frame. Hopefully I wont find myself skidding down the road on a unicycle one day.
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Old 09-02-2014, 07:54 PM   #10
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Default Re: Bolt-on hard-tail Problem

I would build up the back side of that boss w/ a little extra weld just so there was some more meat there. you will probably have to redrill the hole after welding since it will try to shrink the diameter.
at least that would give me a little pc of mind

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Old 09-02-2014, 08:18 PM   #11
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Default Re: Bolt-on hard-tail Problem

Quote:
Originally Posted by Swearfinger View Post
Thanks for the input everybody. I measured it up and the holes are aligned. I guess they didn't weld frames using jigs back in the day. My crude-style measuring shows that the offset-holes are square to the frame. Those "exhaust mounts" were welded differently from each other. One is welded to the frame farther forward, so when they punched those holes, the one is offset.
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Old 09-03-2014, 12:52 PM   #12
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Default Re: Bolt-on hard-tail Problem

Since most of the load will be to the top of the hole, I think you're fine. But if your nervous about it wrap some flat bar around the radius and fill both side of that with weld. I would still put some weld on the bottom joint after its bolted up.
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