Porche brake caliper

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I've got a brake caliper of a 1980 Porche 911 that has a broken ear where one of the mounting bolts go.I'm not looking for people to tell me not to weld it but rather which of my filler choices would perhaps be the best choice. I've got some 3/32" Ni99 stick rods that if I use would end up having the flux knocked off and polished then Tig welded or I've got some silicon bronze Tig wire , and last but not least I've got some Inconel 625 Tig wire.This piece is cast iron btw.No matter the filler it will be Tigged because it is a pretty small repair and stick welding it would make for a messy repair.I will opt for pre-heat and to let it cool as slowly as possible.Looking for suggestions from people that have actually made these types of repairs and not a wag.Another option is to braze it up with brass brazing rod. I'm all ears.Thanks
Reply:Originally Posted by Showdog75.I'm not looking for people to tell me not to weld it . . .Looking for suggestions from people that have actually made these types of repairs
Reply:I think you know that most on this site will consider this a bad idea. maybe not as bad on a weak slow beater of a car, but come on, you own a 911, repair it properly.Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:sorry guys ...... but i say do it cant tell you what filler cause i dont know that kind of cast it is but (cast steel ,cast iron , cast aluminum ,ect) but dont braze it it is not strong enough build it up then drill itLincoln Power Arc 4000 Thermal Arc Fabricator 252 iThermal arc 186Thermal Arc 26 tigTweeko 200 amp spool gunHobart AirForce 400WP-17V-12R
Reply:Originally Posted by Showdog75I've got a brake caliper of a 1980 Porche 911 that has a broken ear where one of the mounting bolts go.I'm not looking for people to tell me not to weld it but rather which of my filler choices would perhaps be the best choice. I've got some 3/32" Ni99 stick rods that if I use would end up having the flux knocked off and polished then Tig welded or I've got some silicon bronze Tig wire , and last but not least I've got some Inconel 625 Tig wire.This piece is cast iron btw.No matter the filler it will be Tigged because it is a pretty small repair and stick welding it would make for a messy repair.I will opt for pre-heat and to let it cool as slowly as possible.Looking for suggestions from people that have actually made these types of repairs and not a wag.Another option is to braze it up with brass brazing rod. I'm all ears.Thanks
Reply:Originally Posted by Showdog75I've got a brake caliper . . .  got some 3/32" Ni99 stick rods. . .  silicon bronze Tig wire. . .  some Inconel 625 Tig wire.This piece is cast iron btw.
Reply:I really doubt it is cast iron or cast steel. Porsche works diligently to lighten every component of their cars. Maybe cast aluminum.A simple magnet will tell if it is cast aluminum.
Reply:If its not cast aluminum then it is forged or cast steel. I would weld it with Super Alloy Missile rod. Ive always used that when welding suspension parts for race cars.  Mac
Reply:Im not a fan of welding anything cast that holds up your survival, especially a brake system.
Reply:'80's 911... probably an ATE caliper (if it's the OEM part) which'd make it a nodular iron according to ATE themselves. Available new (obviously not cheap) and from a quick google it looks like a remanufactured caliper would be around the $100 mark given that yours is no good for an exchange. If that's the case then is it really worth ****ing about to patch it up? Google W0133-1598981 and you'll get hits to '75 through '83 911 ATE calipers
Reply:After re-reading my post and the replys I must say I had a brain fart when I said it was cast iron when in fact a spark test to my experiance told me it appeared to be a cast steel. It had a fairly bright orange spark where most iron seems a little darker in spark.I will totally agree with the person that said I should re-think tigging this piece do to higher heat input than smaw but based on my available filler was the reason I thought it was a option.I have done many cast jobs where various types of fillers were spec'ed but when the material is a unknown is where things change.This is for a good friend that is older and will never push his old baby hard and is tighter than banjo string that I happen to owe many favors and based on my personal success rate being by far higher than my failure rate on odd ball repairs I will attempt this repair and suspect I will go with Ni99 and will do it in the smaw process. Good replys and Thanks for the input.
Reply:If he is a good friend to whom you owe many favors i suggest you go buy that part for him and Save the possible heartache of maybe killing him or someone else if God forbid he has to make a panic stop on your repaired part.Personally I would have a tough time justifing to myself or a court of law that I was sure that sh## would hold.Life is where experience is the major textbook.
Reply:Originally Posted by Showdog75After re-reading my post and the replys. . . it appeared to be a cast steel. . . . I will attempt this repair and suspect I will go with Ni99 and will do it in the smaw process. . . .
Reply:He might not push it, but what about the next guy?  Just remember, YOU'RE IT....My name's not Jim....
Reply:.I suggest a compromise:Do the best repair you can, making whatever suppositions you feel proper; then subject the part to destructive testing to determine how correct you were in both the assumptions and the repair work. Then go out and get a replacement part to repay the debt to your friend and explain the situation you've just been through, telling him what you got to learn in the process of the repair.If either of you doesn't understand the point made by most here, just read the thread "It's been a ROUGH Week..." by Black Wolf. It can happen, and it doesn't matter to the victims whether the driver or a defective part was at fault.
Reply:A quick way to differentiate cast iron from steel is to rub filings between your fingers.  If your fingers turn black it is cast iron.  The extra carbon is what is blackening your fingers.
Reply:Where do you Guys draw the line about who can go, how far, in the design and execution of a car, or a motorcycle or an airplane or a sail boat? You know that Orville Wright and his brother didn't have a clue when they built the first airplane?            Ive built several cars,. a couple work trucks, a small boat, a few motor cycles, and Id damn well build an airplane and fly it to.  Of course every one has to learn and you don't want it on your dollar.  Well in this country and a lot of other ones there's way more people put in danger by food, fun, and fantasy, than by learning and doing. Normal people are careful of their fellow man and look before they leap.  But I must say the human race seems to be getting more stupid by the day.  Mac
Reply:Originally Posted by Tool Maker You know that Orville Wright and his brother didn't have a clue when they built the first airplane?
Reply:Originally Posted by Tool MakerWhere do you Guys draw the line about who can go, how far, in the design and execution of a car, or a motorcycle or an airplane or a sail boat? You know that Orville Wright and his brother didn't have a clue when they built the first airplane?            Ive built several cars,. a couple work trucks, a small boat, a few motor cycles, and Id damn well build an airplane and fly it to.  Of course every one has to learn and you don't want it on your dollar.  Well in this country and a lot of other ones there's way more people put in danger by food, fun, and fantasy, than by learning and doing. Normal people are careful of their fellow man and look before they leap.  But I must say the human race seems to be getting more stupid by the day.  Mac
Reply:Stupidest idea I have ever heard of for a $40 part. I would have picked up a brand new caliper (I'd have done them both too) and already have it done and back on the road. Plus you are risking yours and my life doing it your way, since you don't know, nor never will know the composition of the metal, and so you will NEVER know what the exact proper weld procedure should be. Just get a new one and stop wasting your brain power on trying to repair a dirt cheap part. Just because you can weld doesn't mean that every problem needs to be welded.
Reply:Originally Posted by lotechmanA quick way to differentiate cast iron from steel is to rub filings between your fingers.  If your fingers turn black it is cast iron.  The extra carbon is what is blackening your fingers.
Reply:Get another one..You are not doing anyone any good by fixing it..Not at all....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:Showdog75  -  I"d break off the other ear so your repair idea will be twice as good.   Opus
Reply:Just ask yourself" Would I do this to my wife's/ mother's/ sister's car?                              MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Originally Posted by mla2ofusJust ask yourself" Would I do this to my wife's/ mother's/ sister's car?                              MikeOriginally Posted by zapsterGet another one..You are not doing anyone any good by fixing it..Not at all....zap!
Reply:This thread is useless without pictures.Does it look anything like this Porcsch 911 caliper??????Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:I love this site but hate seeing stuff like this that risks public safety.As consolation, I like all the "don't do it; you'll kill someone" replies.  This ample good advice and explicit warnings constitute more then sufficient "due diligence" that Showdog75 has recklessly disregarded.  And there is a permanent public record of his willful negligence.  This won't bring back the person that will be killed by this car, but hopefully this thread helps the family of the deceased sue the *** off Showdog75, take his house and every nickel he makes in perpetuity.Lincoln AC225 & MigPak 140, Lincoln Magnum SpoolGun, Miller Spectrum 375-X Plasma, Syncrowave 200 TIG, Millermatic 252 MIG, Miller Digital Elite, General 7x12" horiz/vert bandsaw, 3' box/pan brake, 20 ton press, milling machine, 12x28 lathe, etc.
Reply:Originally Posted by AquafireI love this site but hate seeing stuff like this that risks public safety.As consolation, I like all the "don't do it; you'll kill someone" replies.  This ample good advice and explicit warnings constitute more then sufficient "due diligence" that Showdog75 has recklessly disregarded.  And there is a permanent public record of his willful negligence.  This won't bring back the person that will be killed by this car, but hopefully this thread helps the family of the deceased sue the *** off Showdog75, take his house and every nickel he makes in perpetuity.
Reply:This guy is sitting in his living room when he hears the doorbell ring.There is this blonde who needs work and is going around the neighborhood asking for some. She sezs "Do you have any work, I need some money"???Guy sezs "Yes, I need my front porch painted, how much do you charge"?She sez "I will do it for $10"Guy sez "Great, paint is in the garage, let me know when you are done"His wife sezs "Who was that"Guy sez "Some girl who will paint our porch for $10"2 hours go by, back door bell rings, Blonde sezs "I'm Done"Guy sez "Great here is your $10"Blonde turns and starts to walk away, turns and sezs "BTW that is not a porch out in the garage, that is a Lexus.
Reply:Originally Posted by CosmicRamblerThis guy is sitting in his living room when he hears the doorbell ring.There is this blonde who needs work and is going around the neighborhood asking for some. She sezs "Do you have any work, I need some money"???Guy sezs "Yes, I need my front porch painted, how much do you charge"?She sez "I will do it for $10"Guy sez "Great, paint is in the garage, let me know when you are done"His wife sezs "Who was that"Guy sez "Some girl who will paint our porch for $10"2 hours go by, back door bell rings, Blonde sezs "I'm Done"Guy sez "Great here is your $10"Blonde turns and starts to walk away, turns and sezs "BTW that is not a porch out in the garage, that is a Lexus.
Reply:I cannot believe someone is actually thinking about welding a brake caliper back together! Second, I cannot believe someone who doesn't even know what filler to use is contemplating welding a brake caliper back together. Just wow.
Reply:Originally Posted by Showdog75I've got a brake caliper of a 1980 Porche 911 that has a broken ear where one of the mounting bolts go.I'm not looking for people to tell me not to weld it but rather which of my filler choices would perhaps be the best choice. I've got some 3/32" Ni99 stick rods that if I use would end up having the flux knocked off and polished then Tig welded or I've got some silicon bronze Tig wire , and last but not least I've got some Inconel 625 Tig wire.This piece is cast iron btw.No matter the filler it will be Tigged because it is a pretty small repair and stick welding it would make for a messy repair.I will opt for pre-heat and to let it cool as slowly as possible.Looking for suggestions from people that have actually made these types of repairs and not a wag.Another option is to braze it up with brass brazing rod. I'm all ears.Thanks
Reply:This thread is useless without pictures. Here is an example.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.