old Harley fins

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I'm trying to weld up some broken fins on an old Harley head. It's cast aluminum. I would like to have something to put between the fins to contain the weld. There is not much room between the fins and it's hard to clean them up when the weld flows to between the fins. Ideas. Thanks, Ron
Reply:If it's cast aluminum, just use steel.
Reply:Copper, 1/8" thick, hopefully,,The copper is virtually impossible to weld to aluminum,, normally, it just falls away.Thinner than 1/8",, the copper will get stuck a little, but, you will not melt the copper.If you melt the copper, the aluminum will be LONG GONE!!
Reply:Good ideas there with using copper.  if I was doing this I'd TIG weld it with no backer plates.   Basically I'd slowly weld  the fins up, leaving extra material  so that I could file to shape.   sometimes using a backer plate you'll inclusions or empty spots.We've done so much, for so long, with so little. Were now qualified to do anything with nothing !
Reply:

Originally Posted by welding1

Good ideas there with using copper.  if I was doing this I'd TIG weld it with no backer plates.   Basically I'd slowly weld  the fins up, leaving extra material  so that I could file to shape.   sometimes using a backer plate you'll inclusions or empty spots.