Brazing.... Cast manifold

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Here was one of todays projects...... braze a fresh water manifold off a tug boat... The problem..... A crack on one of the bolt flanges. The crack does not go all the way through the piece is still attached.http://i147.photobucket.com/albums/r...g/P1010001.jpgFirst I sandblast the area and gouge the sides......http://i147.photobucket.com/albums/r...g/P1010002.jpgBy doing the sides first I can now use a cylinder type carbide bur and open up the crack on the inside without having to worry about breaking the flange completely off.... At the same time I open up the backside of the joints I just brazed, gouging into the filler material I just put in. This will ensure that I have 100% penatration. Then I braze it up......http://i147.photobucket.com/albums/r...g/P1010003.jpghttp://i147.photobucket.com/albums/r...g/P1010004.jpghttp://i147.photobucket.com/albums/r...g/P1010005.jpgLooks like hell huh? Wait there's more..... okay time to clean it up...http://i147.photobucket.com/albums/r...g/P1010006.jpgAfter cleaning the part I had to braze a layer of filler over the flange ear... when I placed a straight edge across all the flanges the one I brazed was not quite even with the others. Even though there is a gasket enough torque on the flange could cause it to break again. A little bit longer and.......http://i147.photobucket.com/albums/r...g/p1010008.jpghttp://i147.photobucket.com/albums/r...g/p1010009.jpghttp://i147.photobucket.com/albums/r...g/P1010010.jpghttp://i147.photobucket.com/albums/r...g/P1010012.jpgAnother happy customer.......     Zap gets all the fun jobs!!!_________________Chris
Reply:Wow. Very nice.Miller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:What filler and no preheat?
Reply:At first I was going to ask if you did that onboard or at the shop, then I think I spotted your welding table and some other accessories. Nice job.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Zap gets all the fun jobs!!!
Reply:Nice job Lorenzo. Those little tugs are workhorses. A friend of mine used to rebuild diesel engines on tugs back in the 70's and 80's.....that didn't sound like a fun job.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Great patch job, looks like new...Good pointers on the fill and stuff.  Thanks Lorenzo.What sorta wax you guys use when grinding non ferrous?Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:What sorta wax you guys use when grinding non ferrous?
Reply:Nice work!  How strong is that compared to what it was when originally cast?  I have never had the pleasure of brazing so i dont know.
Reply:Brazing alloys for iron are usually in the 45-70ksi range which is equal to or stronger than the iron itself.