Aluminum Tube To Cast Iron Heads..

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Another challenge so to type..Customer sent 2 pre made/used heads to us and wanted a 13 3/4" long aluminum tube to be added.."No problem..Give it .010 shrink and all will be well"..Not so fast.. The shrink would work great if it wasn't for the fact that it's gonna be rubber covered and that requires 400 degree rubber...400 degree rubber = one hot tube and then the heads would just fall out during the process...Can't have that now so here's what I came up with...First off the head(s)Came "stock" with 6 holes each on the diameter  (.187 dia holes)The tube..Shrunk in..Not much wall thickness..Here's where I get "creative"Next post.....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:I went down front with a piece of 1/4" aluminum rod and made up some "rivetts"..Taking a hand drill with a .187 drill we drill out the tube thru the holes in the head..Step drill time on the O.D.Leaves me with a nice weld area...Install rivett thru the back..Next post.....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:With the rivett in place I figured I'd just melt it down like filler and all would be good..Not so fast.. Try to weld the rivett first and this is what you end up with..SoooooooooYou weld the tube to the rivett and all is good finally..Rivett welded..(Multiply by 12)Tube machined..The little discoloration is where the rivett is..And thats that..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:Jeez that is brilliant! I am going to remember that one...forever.Nice post Zap.
Reply:I like your style!!-----------john
Reply:Originally Posted by zapsterHere's where I get "creative"Next post.....zap!
Reply:Originally Posted by MicroZoneJust a quick question - why not just weld the inner ring to the outer as shown above? Great job.
Reply:Uh boy, here we go again.  I bet you can "solder" it using some cronatron wire.The brittleness of that thick a section subject to shear stress and not much fatigue likely wouldn't be a problem.I'm just sayin.  I still dream of welding aluminum to steel -- but then I wake up. Anyway, nice job and real sweet idea with the rivets.  You do get all the fun jobs. Last edited by phila.renewal; 08-28-2007 at 07:03 PM.Favorite right now is a Miller Syncro 200.Tons of tools and I blame at least one of them when things don't go right.
Reply:Ugh - didn't think about that, CAST was never stated, so I just concluded it was similar material. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:CAST was never stated,
Reply:Good fix there, Zap.And that's why you get the big bucks.  WeldingWeb forum--now more sophomoric banter than anything else!
Reply:Originally Posted by 69 chevyGood fix there, Zap.And that's why you get the big bucks.
Reply:Why didn't you just weld the aluminum head to the cast iron sleeve with your double-top  secret reverse proton spray gun?  Just kidding Zap!  Nice job and some creative thinking.Hobart 140 Handler w/ gasHyperTherm Powermax 380 Plasmaoxy/acetylene
Reply:with your double-top secret reverse proton spray gun?
Reply:I am probably outa line here but why would you not get an actual rivet (They make them things by the millions and they hold everything from hog feeders to aircraft together)  and install it with a hammer bucking bar and be hours ahead instead of all that lathe and welder time.  Oh wait,, then you wouldn't be able to post it in a welding forum,  and them I wouldn't get to see it.   Never mind...
Reply:Originally Posted by zapster(Besides "welding" pistons into cylinder bores via hi R.P.M.??)
Reply:Originally Posted by BerniepI am probably outa line here but why would you not get an actual rivet (They make them things by the millions and they hold everything from hog feeders to aircraft together)  and install it with a hammer bucking bar and be hours ahead instead of all that lathe and welder time.  Oh wait,, then you wouldn't be able to post it in a welding forum,  and them I wouldn't get to see it.   Never mind...
Reply:Originally Posted by Joe HHours ahead? I'll bet he spent less time than it would have taken to go fetch some rivets and hammer 'em in. I'm guessing that the OD needed to be smooth too.
Reply:Originally Posted by zapsterCheck out the title of the thread...D'OOhhh...zap!
Reply:Great Job Zap!Always comming with something new and fashion!My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:"I bet you can "solder" it using some cronatron wire."Cronatron???? I'm have never heard of that is it like silver solder ??
Reply:You really get all the fun jobs Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:You can weld aluminium to steel, I have seen the end result. They use a method called "Explosion Welding"
Reply:Explosion welding yes... gonna need an ignition soure and lots of fuel.. a 10 lbs bottle might be enough he he.. dont forget a few gallons of good old 87 octane...
Reply:That is very creative...nice way of improvising!ASODBeauty in the Bead!