welding shift fork pads?

[OldStan]

Does anyone have any experience welding and refacing the pads on the shift forks? One of my forks has what I would consider excessive wear. The shift from first to second is sometimes missed, and I suspect the fork is the issue. They don't appear to be bent. I'm guessing they are cast steel, so my wire welder should do the trick, and I think I've figured a method to get the surfaces even. Also how thick are the new pads? From my measurements I'm figuring about .200", but I'm dealing with some wear, so I'm not sure how close that is.

[jerry]

Old Stan, Did them many years ago on our race boxes. Either Hardchrome or in my case stellite put on with the oxy. Finished width 5mm or .196". Groove in gear approx.205". Positioning is important and especially squareness to selector drum bore. I used to finish grind on the cylindrical grinder. Tool and cutter grinder will also do. Jerry

[OldStan]

Thanks for the info. I guess my main remaining concern is if the material from my wire feed will be hard enough. I'm think for the amount of riding I'll be doing, it will probably last longer than I will. I know the results will not be soft, but by no means hard facing.

One side of the worn fork seems to be good, so I plan to work off of it, but I think I'll assemble the shifter assembly and transmission shafts before I do anything and see where everything is positoned in each gear before I start welding. If I screw up too bad I can still replace the fork. I'll definitely assemble everything and check shifting before final case assembly. There's no point in getting in a rush. Okay, there is, wanting to ride, but I'll resist, for now at least. When the weather stays nice it'll be harder.

[jerry]

Dear Stan, I would replace the shift forks with either NOS or good second hand. Jerry

[teazer]

I had several sets welded and ground to size. We took one NOS fork and made a simple jig to set the datum and popped the welded forks on the jig to get them all in the right places.

We even added a third pad in the center, but to be honest, I'd rather use NOS as Jerry suggested

[OldStan]

I had some time to check out George's fine pictures of the transmissions power path in second gear and verified that the only badly worn fork area was for second gear (about .005" wear.) I also took a closer look at the gear dogs and found rounding there. Obviously I'm going to have to address both issues or have a repeat down the road. I imagine welding on the dog surface of the gear to square it up is out of the question.

Would xing the gears pull on the opposite dog surface? Being on a CA it might not even be feasible.

IF I end up going the welding route on the fork I'll probably swap the two so that the repaired area would end up working 1st gear where (in my estimation) it would be less likely to wear.

I spend more time thinking about all this stuff than actually making progress. I like finding alternate solutions to problems. Used parts are the most likely alternative here, but there's always the opportunity for a stroke of genius, or more likely the voice of reason. Thanks guys.

[LOUD MOUSE]

This part is worn for sure and from what ya say of the gear I'd say ya need to take a good look at the shift rollers and the shift drum. .............lm

I had some time to check out George's fine pictures of the transmissions power path in second gear and verified that the only badly worn fork area was for second gear (about .005" wear.) I also took a closer look at the gear dogs and found rounding there. Obviously I'm going to have to address both issues or have a repeat down the road. I imagine welding on the dog surface of the gear to square it up is out of the question.

Would xing the gears pull on the opposite dog surface? Being on a CA it might not even be feasible.

IF I end up going the welding route on the fork I'll probably swap the two so that the repaired area would end up working 1st gear where (in my estimation) it would be less likely to wear.

I spend more time thinking about all this stuff than actually making progress. I like finding alternate solutions to problems. Used parts are the most likely alternative here, but there's always the opportunity for a stroke of genius, or more likely the voice of reason. Thanks guys.