Cast Iron To Cast Steel..

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Customer brought in a exhaust flange from a bulldozer that was broken in 2..Says the replacement part is 600$ from Caterpiller.."Do what you can to fix it please?"Well here is the subjects...I determined that welding the pieces will not happen without some thinking..First I turned a nice spot on the face of the flange to get to the good steel..Found a piece of 1/4" wall tubing exactly the size I needed 3.900 I.D.(5) 5/16-24 button head screws and nuts later..Looks good to me..Next!.....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:Here is the welds..First pass..Second pass..And thats all the passes..Yup..The flange is cast steel and the elbow is cast iron..There is more than one way to get it done..I get all the fun jobs.....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:damn thats good thinkin! i sure wouldn't have thought of that right away, nice work!-NateMiller Trailblazer 302gMiller Spoolmatic 30aLN-25 x 2Idealarc SP200Hypertherm Powermax 600
Reply:I like the idea of using a "flange" for the flange to mate it up.I like those types of repairs.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Nice job Zap, Didjya fix the hole in the side of the pipe too?David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Zap,Now I know what the Nickel TIG rod was for....Kudos to your adapter-style fix.  A question:Did you consider facing off the end of the exhaust pipe, machining a groove in the flange, and then brazing the flange to the pipe?Just an alternative means of fixing this that I dreamt up while studying the photos you posted.
Reply:Originally Posted by David RNice job Zap, Didjya fix the hole in the side of the pipe too?David
Reply:Originally Posted by A_DAB_will_doZap,Did you consider facing off the end of the exhaust pipe, machining a groove in the flange, and then brazing the flange to the pipe?Just an alternative means of fixing this that I dreamt up while studying the photos you posted.
Reply:Looks great!  I'll have to remember that trick.  I have a feeling the customer is going to be VERY pleased with that repair!
Reply:Ingenious repair. Only thing I would be concerned with, are those nuts inside the exhaust elbow. If the nuts drop off somehow, it could wipe out the turbocharger. Maybe weld them to the bolts? Or put a ring in there?
Reply:Wont that leak around the bolted on ring or does he not care?How was it orig attatched?Have we all gone mad?
Reply:Originally Posted by denrepIngenious repair. Only thing I would be concerned with, are those nuts inside the exhaust elbow. If the nuts drop off somehow, it could wipe out the turbocharger. Maybe weld them to the bolts? Or put a ring in there?
Reply:What snoborder said.I don't get that part either. Isn't that a leaky exhaust?Did you weld two parts together or all three? I can't tell by the pic.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:From the looks of the rust on the other end of that elbow, there hasn't been anything substantial on the other end of it for a looooong time.
Reply:Originally Posted by SandyFrom the looks of the rust on the other end of that elbow, there hasn't been anything substantial on the other end of it for a looooong time.
Reply:Originally Posted by denrepIngenious repair. Only thing I would be concerned with, are those nuts inside the exhaust elbow. Maybe weld them to the bolts?
Reply:Originally Posted by Joker11What snoborder said.I don't get that part either. Isn't that a leaky exhaust?Did you weld two parts together or all three? I can't tell by the pic.
Reply:Very nice work as always and the inginuity is top notch. I think that even a high temp RTV will burn up if that is the elbow that conects to the turbo. that thing will probably see 12-1300 degree EGTs.  But I think the leak would only be substantial at higher boost levels, since there is higher exhaust manifold pressure at these points.  But awesome fit up and idea!!
Reply:nice fix zapChuckASME Pressure Vessel welder
Reply:Seriously zap, i envy your skill. I had my 115v stick welder out today and could even get a couple of 1/8 plates to "stick" together. lol. Like i couldn't get a weld pool (not enough amps maybe.). I hope to be half the welder most the guys here are.______________Clarke 95  Lincoln 135  Lincoln AC 225 ---------I'm an idiot, please talk slowing and simple.
Reply:Thanks everyone..You learn to do much with so little because of the circumstances at times..And you carry that around for life..I learned alot at the Dragstrip when "We have to make the next round one way or another!!!!!!!!"Improvisation is key..Don't always look at somthing for what it is..Look at it for what it can be.......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:those are nice welds mine are sloppy like dog jowls.