Sometimes a man has got to get brazen... Cast iron housing repair

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Remember the grenaded diesel engine I cobbled up for one last run?While mechanic was changing the engine, a crack was "found" in the in the cast-iron flywheel housing:Attachment 21643I pulled the crack closed with a clamp, and cut a heavy bevel on both sides of the casting.The "found" crack was actually caused by a mishap; an unnoticed small difference in the replacement engine, caused a bind as the housing was being tightened. The repaired housing shouldn't see the same stress againOnce the oil burned out of the casting, the bronze tinned and flowed with an excellent bond. Of coarse the crud is flux run off.LH outside housing, RH Inside:Attachment 21644If the oil didn't stop wicking out soon, I was going to fill the pressure washer with acetone. Once the V was filled, I finished the repair by flowing a wide  cap over it; to help distribute stress:Attachment 21645I was going to add some heat, and work the cap into some nice ripples for you guys; but then I thought about having a whole new crack to repair!Here's how it fits on the engine:Attachment 21646That leaves one picture.How about the dentist's tools?Attachment 21647Last edited by denrep; 10-19-2010 at 11:33 PM.
Reply:You 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:Nice job.  Should last forever.I love my die grinder.  Bits are a little steep, but last a long time.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Dang DENREP!  When did you get all fancy with the camera and start making those good illustrations?Looks great.  I would have like to have seen it done.   I  always hear about brazen but never done it. weld it like you own it
Reply:A little off the the subject but I have some pics I tookof a grinder I bought for reaching hard get at places. If David or some one wants to put them up I will send them .
Reply:This thread raises the question: are there different brazing rods, IE RG45 & 60, ER70S-2 & 6. Is the bare rod the same metallurgy as the flux coated? Are there different tensile strengths? Or is it just brazing rod, period?Why did you Vee it instead of using capillary?And why does the sun come up in the east? TIA, Craig PS: I'm still fascinated with the hose clamp on the rod journal to hold oil pressure.9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Originally Posted by Craig in Denver This thread raises the question: are there different brazing rods, IE RG45 & 60, ER70S-2 & 6. Is the bare rod the same metallurgy as the flux coated? Are there different tensile strengths? Or is it just brazing rod, period?Why did you Vee it instead of using capillary?And why does the sun come up in the east? TIA, Craig PS: I'm still fascinated with the hose clamp on the rod journal to hold oil pressure.
Reply:Originally Posted by Hammack_WeldingYou are a bit confused.  Brazing is not welding.  To my knowledge brazing rods are pretty much the same flux coated or not. RG45 & 60  and ER 70s-6 etc... are not brazing rods.  They are for copper coated steel filler rods for welding. Brazing is a bonding process where as welding is a fusion process.   Nice work Denrep.
Reply:Great job, looks nice.One question WHERE'S THE DIME?????I r 2 a perfessional
Reply:where can i buy some die grinder  bits such as in denreps post?
Reply:Thanks for the compliments everyone.Craig in Denver - Capillary action is usually used on tight fitting sections, especially those joints engineered from new for such a fit. Tight fitting tube ends are an example. For repair work, it would be very difficult to get the braze to wick and stick in a small dirty fracture. Although even with wide open repair work, using capillary action or wicking to feed the filler, insures that ideal work temperatures have been reached, and a good bond is taking place.Brazing's strength lies in a good surface bond, more surface area, more bond. Veeing adds surface area, which equals strength.There are many different brazing alloys. I don't know exactly where the fine line between soldering and brazing is, but silver solder sticks are very similar in appearance to brazing rods.Weldbead - The cutters are called carbide burs or  rotary files, most any cutting tool supply house would have them.
Reply:that thing must have been under a lot of pressure to crack like that
Reply:Originally Posted by denrepCraig in Denver - Capillary action is usually used on tight fitting sections, especially those joints engineered from new for such a fit. Tight fitting tube ends are an example. For repair work, it would be very difficult to get the braze to wick and stick in a small dirty fracture. Although even with wide open repair work, using capillary action or wicking to feed the filler, insures that ideal work temperatures have been reached, and a good bond is taking place.Brazing's strength lies in a good surface bond, more surface area, more bond. Veeing adds surface area, which equals strength.There are many different brazing alloys. I don't know exactly where the fine line between soldering and brazing is, but silver solder sticks are very similar in appearance to brazing rods.
Reply:Craig, The terms Welding, Brazing,and soldering can technicly basicly be summed up this way.Fusion Weld-Filler material same as base material with same melthing temperature....within reasonBrazing-Filler metal melts at lower temperature then base material, but higher then 650 FSoldering-Filler metal melts at a lower temperature then base material , lower then 650 FHowever it does get confused with other more specific terms for some processes, but here are some examples.lead/tin on copper-Solderingcopper on copper-Fusion WeldCadmium on stainless-BrazingBronze on Steel-BrazingBronze on Bronze-Fusion WeldingSilver ( over 650F ) on stainless-Brazing Lead on Lead- Fusion Weld ( Lead Burning for the old timers)4043 filler on 3003 aluminum-Brazing (Think its not? Ill show you a "sweated" in fuel tank fitting using that exact combination)Most of the traditional bronzes used for OA brazing fall into the "gear bronze" or "Tin Bronze" category and have strength accordingly.That repair was well thought out, and should provide a service life in excess of the original part if done correctly. Using a TIG process, even with a silicon bronze filler, is not as ideal of a process since you are still causing a rapid heating and cooling cycle due to localized heat imput. That and quite honestly the Tig doesnt handle oils and grime like a combustion envelope, it instead forms gasses that cause porosity, poor adhesion, and other failures. Sometimes we have to ignore the age of a process, and focus strictly on the engineering principals that go into it when choosing a method for repair.
Reply:Makoman:Thanks for taking the time to answer my questions. As a retired desk jockey, I wasn't exposed to much outside of my home garage. I like learning about all welding processes. I have almost 3 dozen welding books, and most of them have been read at least 80%. When someone like Denrep takes the time to photo and explain a repair, I'm fascinated by the ingenuity of problem solving. Gotta luv the internet. 9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Originally Posted by weldbeadwhere can i buy some die grinder  bits such as in denreps post?
Reply:Originally Posted by weldbeadwhere can i buy some die grinder  bits such as in denreps post?
Reply:Matthew...You would be surprised how little pressure is required to crack cast iron. When the pressure is applied in the manner the casting is designed to handle it is tough stuff, but when it is applied in a different manner it doesn't take much at all to break it.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Nice Job.Good show on a brazing project as we don't seem to get many posted here.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.