A gentleman phoned about a mirror that had broken off his Honda Gold wing. From his description over the phone it sounded like a straight forward weld it back in place. He asked if it would be possible to do this while he waited as he lived a long distance from us. We said yes and booked him in.
Where the mirror mounted it had broken out a triangle of plastic which included the holes for the bolts. The twist was the triangle had broken into three pieces which were a big problem, it took some time to work out how they went back together, then each bit was welded to each other, trying not to put too much heat into the plastic; this would have been almost impossible on a very hot day. When finished we came up against another setback, the welded piece was a bit smaller than the hole it had come from.
Sometime later after we had worked out how it should align,we tacked it in place and a number of spot welds were placed to give it more strength, while we made sure that the bolt holes lined up properly with the base of the mirror. Then slowly we started filling in the gap by over welding the area. The build up of heat was causing a bit of trouble slowing progress, so allowed it to cool a bit after each over weld.
After the best part of three meters of welding rod the repair came to an end. The customer was over the moon with the quality and precision, so were we.