airconditioner condenser repair

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A while back another driver hit me at a truckstop. Part of the damage was a hole in the condenser. They told me that the new ones were too thin and poor quality to fix. So that meant that I had to try. They were mostly right, they areba lot thinner and harder to weld than the older ones I used to fix. Here is the condenser before I started.This is the smallest tungsten and cup I had, which is too big for material this thin.I cleaned it up as best I could so I could try to just weld up the leaks. That went about as I expected, not good. I didn't have room to get down on the sides far enough to get a seal. Plus there is the oil to deal with from inside, and I think the aluminum isn't the greatest either.  I'm also out of practice some too. I think I could have done it back when I was doing it daily. This is what it looked like after the first try.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:So I went yo plan B, cut the 3 leaking runs so I had access so I could weld them shut. The main tube welds were easy, the runs tubes were tough. Took several tries to get all the pin holes sealed up but I got it done. Not the kind of repair you could do for a customer, but I could use it myself if I need it.Not a great demonstration of  a good repair, and it wasn't meant to be. I just wanted to see if I could, and to have a bit of fun on a rainy day off.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:I've done it too but they usually don't hold up too long as the balance of the coil is weak and it blows someplace else. Roadwash is a different story however as the damage is usually concentrated in a single area as opposed to deterioration. A hot bath in sodium carbonate, (Cascade dishwasher soap) usually removes the trace oil trapped inside followed by a good rinse.I have also found that "Hysol" brand epoxy paste work really well if you pack the tubes with a bit in the end, pinch them shut with needle nose and roll the tube around with the jaws finally crushing the tube between the jaws. I've tested to 400psi using nitrogen without leaks.SlobPurveyor of intimate unparalleled knowledge of nothing about everything.Oh yeah, also an unabashed internet "Troll" too.....
Reply:I have done a few oil cooler repairs similar to this. I have found it best to cut the cores at the tanks on both sides and weld the openings on the tank shut. Welding that thin aluminum is a pain. Glad to see you got it handled. Nice repair!Last edited by Burnt Glove; 05-08-2015 at 12:42 AM.Operating Engineers Local 3Lincoln SA 200Victor TorchDewalt Grinder10 lbs SledgeWhat more do ya need!
Reply:I do these repairs fairly often.  I always use a special low heat flux and solder made for condensers and evaps.  Much more forgiving of PAG and mineral oil etc.  You apply the flux, then heat, then more flux and it's ready to solder.  The solder will even make good joints between aluminum and copper and it will build up enough to use as reinforcement.  It's also easier to get the heat inside the cores for solder than it is to get a tig torch inside.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:Do you have a name for that stuff? It's not likely I'll do a job like this again, but you never know. Until I came here I had no idea you could solder aluminum.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw