15 liter Caterpillar oil pan re-repair

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Pan cracked, was removed mig welded reinstalled and cracked again. Removed and mig welded again- leak. Repeat. Mechanic said this made 6th time he pulled the pan. Owner of truck decided to send to me for repair. Pan was warped quite a bit around welded area. Learned long ago that tig over a bad mig weld very seldom repairs problem. Plasma cut all signs of mig welds, cut and loosely fit flat stock in opening and welded. I like big gaps and when welding castings. Welded everywhere but flange, clamped flange and then welded it last. Got most of warp out of pan rails. Welded one pass outside and one pass inside giving through weld. Air tested no leaks. Syncrowave, 4943 filler. Attached ImagesEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:more pics Attached ImagesEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:Always great to see your work. We haven't seen you post much lately. I hope that's because you've been busy..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Great post and fantastic repair as always. Maybe the mechanic will put down the mig and start sending you the work the first time around. I think everyone would have been happier.
Reply:Nice job!!
Reply:Nice work. I just got some 4943. Can't wait to try it.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Nice job! I wonder what a new replacement pan would cost.
Reply:Nicely done Every time you, and the others, post up work like this - it makes it a lot easier for me to fix my next random repair.Thanks for posting Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Nicely done, nice write up and photos too.  Looks like it's fixed the right way finally.Lincoln Precision TIG 185.Flex-Loc 150 torch.Super-Flex hose.Lincoln MIG 180.Victor Oxy/Act torch set.DeWalt Bandsaw with SWAG stand
Reply:Nice save!I like your rail straightening system...I clamp them to the bench...Fixed one of those a couple y months ago in almost the same place...I was the first one to play with it so it was much easier than what you went thru....Wonder if there is some sort of manufacturing defect because the pan I did was rather new.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:last time i checked a factory cat oil pan is 900ish dollars.   You can get a repoped crash part oil pain for 600ish.      Cat uses some sort of black magic engineering on their drain plugs,  you can put them in with a 1/2" drive socket and you will need a 3/4" bad *** impact to get the some beach back out.   First time i changed the oil on our brand new 06 kw with a c-15 i had to use a 5' pipe on a 1" drive ratchet to get the drain plug cracked off to drain.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:I have seen a few cracked in the same place, I figured it was due to operator error by the way the gasket was bulging out of the gap between block and engine. Not like any mechanic is going to want to own up to breaking a chunk out of a cast oil pan by overtightning the fasteners. I did the same basic fix, channel it out with a carbide burr, clamp to table and weld away, did mine with 4047.Miller Big 40GMiller HF-251 D High FreqVictor OA Lincoln 135 MigMK 3A CobramaticBridgeport J HeadCronatron OxylanceRadnor ACAG TorchWeldcraft TIG Torches1 blown knee and two 5 Gallon pails away from being a hero.
Reply:Originally Posted by DSWAlways great to see your work. We haven't seen you post much lately. I hope that's because you've been busy.
Reply:Originally Posted by motolife313Nice job!!
Reply:Sorry if my question is dumb but I'm kinda a noob.  That's cast aluminum right?  I didn't think you could weld cast aluminum, i thought it could be brazed though.  I ask because I have a mig welder that does aluminum and I don't want to weld something im not supposed to, why does it not hold up but tig does?  Anyways nice fix, do you expect it will last as good as a new one?
Reply:very nicely done! I've been using 4943 for probably 6-8months or so. I've been really happy with it. Seems to weld pretty much identically to 4043 but with the added tensile strength.-DoogieMiller 350PMiller Trailblazer 325 EFI w/ Excel PowerLincoln LN25 suitcase welderXMT 304/22a feederMiller Syncrowave 350LXMiller EconotigHobart Handler 140(2) Uni-Hydro 42-14Hypertherm 65 plasmaWEBB Gap bed lathe
Reply:what was the sheet material used?
Reply:Originally Posted by bigkevSorry if my question is dumb but I'm kinda a noob.  That's cast aluminum right?  I didn't think you could weld cast aluminum, i thought it could be brazed though.  I ask because I have a mig welder that does aluminum and I don't want to weld something im not supposed to, why does it not hold up but tig does?  Anyways nice fix, do you expect it will last as good as a new one?
Reply:with the 600 for a replacement I wonder how close they came to that by going to the first guy and then the right guy last?
Reply:Although 4943 does indeed have a higher tensile strength than 4043 filler, the ductility is about  1/2 of 4043.http://www.maxal.com/4943_datasheet.pdfThere's no free lunch.  Just an FYI.Also, watch out for the cut edge on aluminum when using air plasma cutting.  There is usually a varying degree of oxidation on that cut edge, which may or may not have to be 'mechanically' removed (carbide burr) before welding so you don't have excess porosity or other 'crap' in the weld.  GTAW and a skilled welder will often let you dwell on the puddle and let the crud/crap float out while making the weld.  GMAW doesn't give one that same 'dwell' ability when making a weld though.Good call (as usual    ) on removing the 'crap' weld repair attempts and getting back to (relatively) sound metal in making the repair.    The best laid schemes ... Gang oft agley ...
Reply:Chances are the MIG warped it, then when tightened, it just cracked again.
Reply:Originally Posted by MoonRiseAlthough 4943 does indeed have a higher tensile strength than 4043 filler, the ductility is about  1/2 of 4043.http://www.maxal.com/4943_datasheet.pdfThere's no free lunch.  Just an FYI.Also, watch out for the cut edge on aluminum when using air plasma cutting.  There is usually a varying degree of oxidation on that cut edge, which may or may not have to be 'mechanically' removed (carbide burr) before welding so you don't have excess porosity or other 'crap' in the weld.  GTAW and a skilled welder will often let you dwell on the puddle and let the crud/crap float out while making the weld.  GMAW doesn't give one that same 'dwell' ability when making a weld though.Good call (as usual    ) on removing the 'crap' weld repair attempts and getting back to (relatively) sound metal in making the repair.
Reply:Originally Posted by drujininChances are the MIG warped it, then when tightened, it just cracked again.