How do you repair cast aluminum ?

[casadejohnson]

Apparently, I am an idiot. I was working on my EFI conversion today and I accidently knocked my Edelbrock performer upper intake manifold off of the work bench. It hit the floor and broke one of the ears off ( Where the bolt goes through to attach it to the lower intake) . I have never weldeed aluminum and I'm not sure this is somthing I want to even attempt. Would a JB weld or other cold welding process work? How about the Durafix welding rods that I have seen that allow you to use a propane torch to weld it? I have seen ads for this stuff but I don't know if its any good. Here is a link to the product I'm talking about.

http://durafix.com/

Anyone have any input or a similar experience?

 

[SnwMnkys]

Ive seen a few people break those ears off, everyone ive seen theyve just taken it to a local welder to have it done, and then to a machine shop to mill that sealing surface flush.

 

[NicksTrix]

ditto snwmnkys response. an alum intake is no big deal to weld if you know what you're doing and have the proper tools. don't try messing with it if you aren't equipted, you'll just get frustrated and make a mess. it's a quick fix to put an ear back on.
good luck
nick

 

[BUCKETOBOLTS]

I can say I've been there and done that. No big deal just make sure you get the gasket surface flat so you don't get a vacuum leak. You can file it carefully or have it fly cut in a milling machine. We used to do a little experimenting cutting, grinding, and welding on the ol' factory 5.0 manifolds back in the day.

 

[ponch0v]

Got a sample of this stuff to fix a manifold at the local welding supply, worked just ok. Aluminum is a good conductor of heat so you have to heat the whole manifold up to the proper temp before the rod will flow properly. thats a lotta gas before the base metal will accept the rod. this repair would be good on a small part but not for large ones.
Next time, im off to the weld shop

http://www.aladdin3in1.com/products.htm

 

[mtkawboy]

I had a broken ear on a rare aluminum 68 Z/28 intake repaired by a machine & welding shop a long time ago and have never had a problem with it. Dont even think about JB Weld it will break right off again. Id take it to a pro.

 

[wildbill]

Find a good weld shop and you will be good to go. Have done then and alum bellhouseing's good luck. Bill %)

 

[casadejohnson]

Thanks for the advice. Looks like I'll be putting my project on hold untill I can get it welded next week.

 

[Bronchole]

My boss was telling me the other day about a material that can braze aluminum and the resulting joint is stronger than the original aluminum, He found it when he was looking for alternitives to laser welding a joint an a part. If anyone is interested I'll get the information from him during the week,

 

[bmc69]

We use Alladin "3 in 1" brazing rod to repair small or thin aluminum castings. While tricky to use, the strength of a properly executed brazing is amazing. In the case of something like a manifold or bellhousing, I would fire up the TIG machine and fix it. However, the brazing rod works and only requires a propane torch and a small stainless brush....and some practice.