Welding a motorcycle frame: Advice from an expert

Q: I just ran across the article you wrote about gas metal arc welding (GMAW) machines in the July/August 2004 issue of Practical Welding Today. Your article was very informative. I will be purchasing a welding machine soon and would like to know if a GMAW machine can handle a motorcycle frame. Any advice would be greatly appreciated.

A: GMAW is awesome because it’s easy to learn, and the equipment is relatively affordable.

Be sure to check around, though, because the prices of machines vary. Every welder has a preference, but most of the name-brand machines out there are built well. A good welding supply store will let you test them out.

Welding Machine Advice

Some really nice 110-V machines on the market are real workhorses as long as you have the right fuse. And yes, you can use it on a motorcycle frame as long as it’s made out of steel or steel alloy. It’s a great process for a bike frame because the heat is concentrated in a small area.

As a matter of fact, I recently welded a crack between the kick starter and clutch plate on a dirt bike. I’d recommend using a 75 percent argon/25 percent carbon dioxide mix for shielding gas. It makes a shallow, uniform puddle without excess spatter.

Motorcycle Frame Welding Tips

I’ve used gas tungsten arc welding (GTAW) and shielded metal arc welding (SMAW) on aluminum, but not GMAW. I think GTAW would be the best choice because of its heat control, being able to see it well, and its smooth bead.

Be sure you don’t copy some of the bad safety habits I’ve seen on some of the cable TV shows. Those guys close their eyes to make tack welds instead of wearing a welding hood; evidently they don’t realize their little onionskin eyelids allow ultraviolet rays to pass through them. Of course, follow all the safety steps, being especially careful not to weld around or on any containers with unknown contents. Almost every year I read about someone getting hurt or killed when a container either explodes, burns, or causes toxic poisoning.

Good luck, and happy riding!