HELP Aluminium block lug?

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I found a broken lug for the starter on my AEAD 200LE ! Thinking I can tig it back on but just learning to tig alumininum!How hard is it to go vertical?  Any other possible way to fix it?I have a spool gun should I go that route?AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Hey houseoffire,It would be best to post some pics of the broken lug & block area. I have used both spoolgun & TIG for varying broken aluminum lug applications. NEED PICTURES.......DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:I will try to get some pix ASAP. I'm at work right now.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:For someone starting out it would be much easier to orient the machine so you can weld the lug in the flat position.    pics would help thoughVantage 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:Hey Dualie, I dont want to pull the engine but I can tilt the trailer back and even raise it up to maybe 45 degree angle.  Flat would be best for me for sure!   Do you think I should spool it or tig ?  I'm working in the firehouse today and christmas but when I go home I'll take a picture and post it.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Here are pix of my broken lug!Dualie, I can and will make it on the flat.  I think tig for better control, what do you think? Attached ImagesLast edited by houseoffire; 12-26-2011 at 03:59 PM.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:First clean it.   I would Vee two spots, tack it in then vee out the rest and  tig weld it.  Die grinder with a bit for aluminum.    Mostly get it clean.It looks like you could get your torch all the way around.  Keep the crankcase vented well.  I would do i t flat.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Hey David, yea I 'm going to use aluma prep to get it real clean!  I guess I could use my dremel to V the sides then I was thinking of building the weld up for more strength.  Tig is the call, right?AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:I would give it a couple passes with the machine at full cleaning without actually melting the metal before welding it.
Reply:To me, it looks a better candidate for AL brazing (as is with that nice interlocking surface) than for welding with any process.Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Lots of great advice from those that apparently have never weldedon a crankcase--that has fuel and fuel vapor inside; and creates copiousamounts more-when hot from welding. Can actually blow flames, repeatedly and in not a nice way, in ways that can hurt you.At the minimum suggest you:-drain oil out-wash out and flush out with water/detergent solutionthat will cut the oil-leave the fill and drain plugs-outIdeally this should be inert gas purged, for zero O2....but inert gas purging isn't understood by many of the 'pro's' on this forum.Repair sequence is;-TIG tack up first--then carbide groove thru tacks sequentially  weldingto maintain position of the lug--check fit with fasteners and part-priorto welding out.-4043 is compatible alloy to cast-Rick V--The tackup, groove, then weld out is a far stronger repair that AL soldering or 'brazing' can hope for.Last edited by dave powelson; 12-26-2011 at 07:01 PM.Reason: additionBlackbird
Reply:Dave, I'll follow your suggestions, I'll get another tank to back gas thru the drain hole!  Thanks.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:When grinding don't use any stone that has Aluminum Oxide.  It will make a mess of your weld.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:can you borrow an oxygen monitor from the FD?    Inert purge would be the best bet, tape a hose into the drain and check the oxygen levels coming out the fill.I agree with all the above in saying V grove 2 sides and weld. then V grove the other two sides with a carbide burr.TIG is your go to on this one with 4043.the only time i have ever welded on "engine blocks" was after they were stripped down and cleaned in a hot tank and completely open.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:Dualie, I can monitor the O2 before I start the weld!  I will follow your sugestions.  ThanksAEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:how about a washer and nut on the backside so you can bolt it together to weld?
Reply:Originally Posted by dave powelson-that has fuel and fuel vapor inside; and creates copiousamounts more-when hot from welding.
Reply:I looked closer into the hole and it does appear to be a seperate chamber! I had drained the oil prior to popping  the cracked lug off so I thought there was oil in there!  I just took another look with a flashlight.It is in fact a seperate hollow chamber, no oil or fuel was in there! There is another lug that passes thru, should I still back gas, purge or would that no longer be necessary ?AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:18 posts, 5 days later its still not done?   I get these in my shop, usually its motor mount boss on an engine or transmission from a mini van that was in a wreck.  Ihave a couple collision shops that bring me that stuff.   They take me from an hour to a few hours.   If its not accessible, I have the customer pull the part.Just do it!  Now you know it will not even leak.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I'd build a new boss up with new metal, drill and tap the thing for a threaded insert and be done with it.  Chances of getting the old one back on in the same alignment are slim. Been there, done that.Two turn tables and a microphone.
Reply:I'm going to attempt to weld it this weekend!  If that don't work I'll build it up and machine it!I'll post my fix when its done.  Thanks to all!AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Originally Posted by David R18 posts, 5 days later its still not done?   I get these in my shop, usually its motor mount boss on an engine or transmission from a mini van that was in a wreck.  Ihave a couple collision shops that bring me that stuff.   They take me from an hour to a few hours.   If its not accessible, I have the customer pull the part.Just do it!  Now you know it will not even leak.  David
Reply:Originally Posted by PangeaI'd build a new boss up with new metal, drill and tap the thing for a threaded insert and be done with it.  Chances of getting the old one back on in the same alignment are slim. Been there, done that.
Reply:Welding aluminum castings is very much hit-or-miss. I can see some pretty coarse grain on the break there. It looks like a $hitty casting.To me, it looks a better candidate for AL brazing (as is with that nice interlocking surface) than for welding with any process.
Reply:Aluminum Brazing is like trying to roast a pig on a hairdryer. Hili arc the damn thing, its so simple its like 4 minutes work since you already have it out and clean. It wont even hurt the threads if you screw a well lubed bolt in the hole. Ive probably welded a thousand things of this caliber in the last 40 years. I would charge you more for the bother than for the job.  MacThats gonna be one dirty aluminum weld! I hate welding used cast aluminum engine parts! When welding this lug you aren't gonna get a normal aluminum puddle. You will get a puddle under grime, oil, oxidation, and who knows what. The puddle will always be on the edge of falling out so be careful with the heat. Get the puddle going and just keep cramming filler in threw the junk.
Reply:Well it's done!  here is a picture , mid way point and the finished product.It was harder to get in there than it looks!  I ground v's in the joint on the sides prior to starting and put 3 passes total to build it up!  Keep in mind I'm a hobby guy right now and have just recently started tig aluminium!  and the VERDICT is ? Attached ImagesAEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:looks like you got it and looks like it will hold.PT185?Thanks for posting.   DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David Rlooks like you got it and looks like it will hold.PT185?Thanks for posting.   David
Reply:Looks good enough for the application.   should out last the machineVantage 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:Originally Posted by DualieLooks good enough for the application.   should out last the machine
Reply:Nice job! How was it welding that cast? Some castings are better than others.
Reply:Originally Posted by VPTNice job! How was it welding that cast? Some castings are better than others.
Reply:Originally Posted by houseoffireI looked closer into the hole and it does appear to be a seperate chamber! I had drained the oil prior to popping  the cracked lug off so I thought there was oil in there!  I just took another look with a flashlight.It is in fact a seperate hollow chamber, no oil or fuel was in there! There is another lug that passes thru, should I still back gas, purge or would that no longer be necessary ?