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  1. #1

    Ultra 250X project

    I bought a ultra 250x with a blown motor. Number one cylinder dropped one valve and smashed the piston and head. Cylinder is damaged. Buying a new head and cylinder is not worth it. I am thinking of welding the head and repair the cylinder and put a new piston there. New updated head are available and my dealer claims they do not crack.
    Has anyone welded and cnc milled a damaged head before? Is it worth it?


  2. #2

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    If you can get to the spots where ALL the damage is with a TIG torch and tig it up I do not see why not. Also you don't need to have it CNC'd. Just a good seat and guide machine as well as a good head surfacing machine will work. Let us know how it goes. I welded up a couple of BMW heads that were O-ringed and filled the groves in for a local shop. Hey it's what they wanted. A good filler rod to use is MaxeT 4943 made by Hobart. I use this rod all the time. Good stuff.
    T.J.

  3. #3
    Take the time to smile sirbreaksalot's Avatar
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    Quote Originally Posted by JakeDale View Post
    I bought a ultra 250x with a blown motor. Number one cylinder dropped one valve and smashed the piston and head. Cylinder is damaged. Buying a new head and cylinder is not worth it. I am thinking of welding the head and repair the cylinder and put a new piston there. New updated head are available and my dealer claims they do not crack.
    Has anyone welded and cnc milled a damaged head before? Is it worth it?
    when you say repair the cylinder ???????????

    you do realize its a coated bore right !!

  4. #4
    Yes, cylinder is NSC coated. Will probably send to Millennium tech or some similar shop for rework of both of them. Does anyone have any recommendations regarding shops?

  5. #5
    Take the time to smile sirbreaksalot's Avatar
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    personally I would just go with a new 2010 model OEM cylinder

    there only 1k , and then you get the proven life & quality that they give

    I've had hit and miss success on aftermarket plating services, I bet after repairing the bores and recoating them you will be getting up there.....

    and from memory they even changed the water height in the cooling passages to reduce GIO
    Waz

  6. #6

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    I've always used powerseal in PA. I think they do heads also. All the cylinders I've given them come back looking like new. Make sure you still clean the cylinder out when you get it back from any shop though. And oil it up for reassembly

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