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Bills Safari Adventure
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Date:  1-2-2011
Number of Hours:  3.00
Manual Reference:  
Brief Description:  OH CRAP

Spent quite a bit of time rotating the frame to spread the oil inside while cutting and bending metal.

I notice a pool of oil on the floor and found the source. See the first picture. The burn through is almost 1/4" in diameter and there is severe undercut leading up to it. The next picture shows the location from underneath. It is on the top horizontal tube just to the right of the tube cluster. The last picture shows the view from the back.

This is in a bad spot. It is right beside a tube cluster of 8 tubes, a very high stress area. There are several problems.

1. Although it is no big deal to weld up a hole that size I don't know if from a structual standpoint if that is a valid repair or if a sleeve needs to be added or the tube replaced.
2. The frame is powder coated. In order to recoat the old coating needs to be sand blasted off and redone.

3. The tubing is full of oil. This will contaminate the weld and fill the powder coating oven with smoke.

I am going to contact a DER and have it looked at.
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Almost 1/4

Almost 1/4"

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View from underneath

View from underneath

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View from rear.

View from rear.

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