cast aluminum intake weld

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HelloI am building an intake manifold for a car. I want to weld an adapter plate on the original cast aluminum intake manifold to bolt supercharger on it. I have a Lincoln Mig pack 140 and Lincoln AC 225 stick. What is the best choice to make strong weld?tanks
Reply:A TIG with an A/C setting if you want it not to leak.
Reply:Originally Posted by phelopHelloI am building an intake manifold for a car. I want to weld an adapter plate on the original cast aluminum intake manifold to bolt supercharger on it. I have a Lincoln Mig pack 140 and Lincoln AC 225 stick. What is the best choice to make strong weld?tanks
Reply:make a bolt on adapter much easier and no chance of warpage..........  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by B_Cmake a bolt on adapter much easier and no chance of warpage..........
Reply:Originally Posted by PangeaPffffffft! You must think that you are logged on to FASTENERWEB or BOLTTHATCRAPTOGETHERWEB!
Reply:Speaking of warpage.  I just spent about 4 hours using a granite block and sandpaper, sanding the gasket surfaces of a '77 Landcruiser exhaust and intake manifold that were seriously damaged from allowing the engine to run with blown gaskets.  Mostly the cast iron exhaust manifold.  It only took about 3 minutes to do the aluminum intake surfaces.  After all that, It wouldn't idle!!!  Found the bottom of the carburetor was warped too, so sanded that and all is well.  The good old 2'x2' granite block really comes in handy for making sure your sufaces are within a thousandth when you are working on engine parts.  A friend of mine who deals in Landcruisers laughs at me for hand finishing stuff on the granite, but I don't think a shop could get it any closer...just gotta get past the shoulder aches.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:thats pretty crafty. (the granite thing)Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:Originally Posted by DougAustinTX but I don't think a shop could get it any closer...just gotta get past the shoulder aches.
Reply:Originally Posted by DiabolicZWait what??? A machine shop can get flat surfaces beyond a 50RA for multi layer steel head gaskets. That is pretty much a mirror finish. If I saw somebody surfacing my heads on a 2'x2' granite block, I would start looking for push rods in my engine...
Reply:Originally Posted by ironmangq I've seen stuff come from the machine shop that looks great and is smooth but you put a straight edge on it and its warped. Usually happens because of a loose machine that lets the bed rock a little during its travel.
Reply:Originally Posted by PangeaPffffffft! You must think that you are logged on to FASTENERWEB or BOLTTHATCRAPTOGETHERWEB!
Reply:I like "EASY"  and "SIMPLE"  and  "OLD SCHOOL"      words  that let me enjoy my trade.........Nothing wrong with bolts......  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Don't think you are gonna do weld and not machine. Just not that simple.Bolted will have its merits.Speaking of machining  if you have the results after that you state its time for a new machine shop end of story. LOLVinnie
Reply:Originally Posted by VinnieSpeaking of machining  if you have the results after that you state its time for a new machine shop end of story. LOLVinnie
Reply:Originally Posted by 4sfedI disagree here.  How do you expect the machine shop to hold the manifold while it's being machined?  A proper fixture to hold the average cast iron exhaust manifold would take longer to make than the hand finishing Doug uses.  The other consideration is the clamping forces needed to hold the part while it's being machined.  There will be a small amount of spring-back when the clamps are removed.  If it really needs to be perfect . . . machine it if you wish, then lap. -jimHey Doug, a quick pass over 24" disk grinder would shorten the amount of time you spend hand finishing.
Reply:My buddy has a performance engine machine Shop and uses a cnc Rottler machine To surface blocks,heads,intakes. He hasFixtures to hold them and come out rightOn the money......you have to have your $hit together to be in that business  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Just about every after market intake is off....seen EdelbrocksOff enough to have air leaks  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by B_CMy buddy has a performance engine machine Shop and uses a cnc Rottler machine To surface blocks,heads,intakes. He hasFixtures to hold them and come out rightOn the money......you have to have your $hit together to be in that business
Reply:Yep.......  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:If he is doing an adapter can't he use a spoolgun?  I'm not saying build a whole manifold with a spool gun but do you think the 140amps is strong enough for a small job?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by ironmangqSmooth and flat are two completely different things. You can achieve very flat surfaces using a granite slab and the right abrassives you can also get very very smooth surfaces. I have hand finished heat sinks on a slab to make them flat and you can get a very smooth mirror finish that is also flat.    Correct MattI've seen stuff come from the machine shop that looks great and is smooth but you put a straight edge on it and its warped. Usually happens because of a loose machine that lets the bed rock a little during its travel.    Not Correct Matt
Reply:Originally Posted by GambleIf he is doing an adapter can't he use a spoolgun?  I'm not saying build a whole manifold with a spool gun but do you think the 140amps is strong enough for a small job?
Reply:Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:I am in the same boat, but i have a TIG.If you dont know the composition of the cast aluminum, what type of filler would you use just knowing that it is cast?Would you in a descrete area  or a cut off part try running a bead on it with different fillers?Not trying to thread jack, but the threads are very similar.Originally Posted by VinnieYou have answered your own question  "A proper fixture to hold the average cast iron exhaust manifold would take longer to make than the hand finishing"It depends on what you want to pay for.Vinnie
Reply:B C Great info but it seems some here don't get it.That bad boy rottler kicks aas.I don't think the top fuel teams have any engine work done without this kind of precision.Or any other hard core racing teams.Just my .02Vinnie
Reply:Yeah NASCAR  teams have 5 axis machines for their Cylinder head programs.....Very trick very repeatable.......  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by shlammedI am in the same boat, but i have a TIG.If you dont know the composition of the cast aluminum, what type of filler would you use just knowing that it is cast?
Reply:Yeah I use 5356 on high stress situations, but have good results with 4043 for most cast situations......But like you said "What works for you"   lol  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by VinnieB C Great info but it seems some here don't get it.That bad boy rottler kicks aas.I don't think the top fuel teams have any engine work done without this kind of precision.Or any other hard core racing teams.Just my .02Vinnie
Reply:Your correct, hand lapping is the final step, After the 5 axis CNC  does all the shaping......No one said anything different?   Im not going to get into a pissing contest with you over something that I don't care about.......I'm happy you have records at Bonneville.......I have things I have accomplished in my racing life also but that's the PAST.......I live for the future.....and I'm just answering a guys question on Welding Web.........Last edited by B_C; 03-22-2011 at 02:38 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:As far as Bonneville,  I did pretty much all the aluminum welding on the inner cooler and blower manifold on Got Salt........So Im no stranger to speed....The Got Salt Racing Lakester.  Here it is sitting quietly where it was left for the night – waiting in line for Tech Inspection.  It runs in the AA/BGL (AA = over 500ci, Blown Gas Lakester) class where the record is 315.766 MPH.  The Got Salt Lakester could “only” muster up a 301 MPH pass. I can’t imagine going 301 MPH and thinking “Man, that was slow”.  There are a number of these Lakesters that resemble Top Fuel dragsters.  I guess it’s cool to go 300 MPH for 4.5 seconds in the 1/4 mile on a smooth asphalt track, but how about going 300 MPH for 2 miles (24 seconds) on a natural (read: not smooth) surface. Twenty four seconds is a long time when the grim reaper is riding in the seat next to you.Note:  You can tell a Lakester from a Streamliner because a Lakester is open wheeled and a Streamliner encloses or covers the wheels.Last edited by B_C; 03-22-2011 at 02:58 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:B C that's an absolute salt racer with no doors has to be a real rush to watch it disappear into the horizon only to return.Nice and basic home engineered from a kit with some sound welding there nice pic also. Once a year what a spectacle.I would like to be there but too close to Brainerd nats Can't spend that mush time away in one month. Brainerd Sturgess Bonneville PS just stole the pic for a new desktop wallpaper.Thanks for the change.Much better than that rottler machine "LOL" No sarcasm in my post.Just my 2¢.VinnieLast edited by Vinnie; 03-22-2011 at 08:11 PM.
Reply:It's a very nice car, they went 317 in 2009 only to break on the back up run with blower failure.......  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Not to hijack, but there's nothing like the sound of a turbofan spinning up to get the paah-ty started.Lookout when the flame goes out, the smoke disappears and it starts sounding like a dentist's drill cause that means they're throwing the trash on the fire.5,000 horsepower in a 1,145 pound car. Zero to 60 in less than 1 sec.Built with a Syncrowave.Last edited by Kelvin; 03-23-2011 at 03:41 PM.
Reply:Yeah I likes the jet cars too, too bad the insurance companies that insure the races don't....  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:I remember seeing the Blue Angels at a show where they also had this turbofan-powered truck tractor...we were waiting to get onto the NAS to see the show and we heard this tremendous BOOM and then saw this black/orange mushroom cloud and I thought one of the jets "encountered terrain" ... ... but it was just the guy in his jet truck vaporizing a whole bunch of kerosene and lighting it off... Imagine pulling 5 G's trying to do a quarter in 5 sec at 300mph+ while burning 5 gallons of kerosene per second. Omma take my dentures out!Last edited by Kelvin; 03-23-2011 at 04:41 PM.
Reply:Yeah pretty impressive.......But just too dangerous for most promoters to  bring a whole show aboard....  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:But after a while, the increasing frequency of the inlet valve, along with the inlet system resonance, becomes absolutely out of phase with each other; and there is a steady declination on the effect of sound pressure, to promote the filling of the cylinder. The intake system also acts as an induction system. The cold air induction systems comprise of bent and snaked pipes, specifically designed to fit into the exact area of the engine, and they also promote extra cooling of the air passing through them, because of the fact that the air has to pass through a longer distance, when it comes to cold air induction systems. k and n air intake