Cracked GMC bell housing

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I need to weld a crack in a bell housing on a 94 GMC 3500HD ,6.5l manual trans.My question is what rod should I use? I'm assuming it's cast aluminum,but I have'nt seen it,yet. I have aluminum and silicon bronze fillers.I would prefer to tig if I could.Just not sure which filler would be best? Thanks guys
Reply:I wouldn't waste the time and money to weld it. Odds are it will crack again. Buy a new one you will be better off.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:I have done tons of cracked alum cases and use 5356..Works for me."V" out the crack on both sides if you can and clean it clean it clean it and when you think it's clean clean it again..Weld up the crack and watch for it to be longer than you can see with your eye..The heat will bring it out.After welding grind it all off and go over it again and again if needed until there is no more crap rising to the surface after each weld..Some castings are no big problem and some just plain suck....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:Originally Posted by zapsterI have done tons of cracked alum cases and use 5356..Works for me."V" out the crack on both sides if you can and clean it clean it clean it and when you think it's clean clean it again..Weld up the crack and watch for it to be longer than you can see with your eye..The heat will bring it out.After welding grind it all off and go over it again and again if needed until there is no more crap rising to the surface after each weld..Some castings are no big problem and some just plain suck....zap!
Reply:Originally Posted by mechanic416I wouldn't waste the time and money to weld it. Odds are it will crack again. Buy a new one you will be better off.
Reply:Originally Posted by curb guyThat was mentioned in the shop,but for some reason,and I don't know for sure,I was only told, that bell housings for 6.5l ,at least the engine/tranny configuration I'm talking about here, are about as rare as 'hens teeth'. Again, that's just what I was told.
Reply:Zapster gave you some very solid advise. Follow it and you will make a quality repair. I usually run a few cold autogenous passes before adding wire to help boil out the crud that is going to appear.Two turn tables and a microphone.
Reply:Originally Posted by Pangea I usually run a few cold autogenous passes before adding wire to help boil out the crud that is going to appear.
Reply:Follow the last 2 posts and you'll be golden! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by Wstmrlnd89639The combo may be rare, but I believe its the same nv4500 that dodge used in the hd manual trucks, which pretty common. I could be wrong though.
Reply:Covered well with previous posts. Just wanted to mention I as well have welded up all kinds of bell housings, trans cases, diff housings, outboard motor lower units, etc.I've welded up my brothers chevy bell housing after one of his buddies pinched something between the housing and motor and broke not 1 but both lower ears off the case. Welded up both sides and it has been just fine ever since. This is in a 9 second car mind you.
Reply:I've welded a bunch in the past, and the prep work is most of the job, I prefer them out of the vehicle, but sometimes you just you don't have the option. I just did this one not long ago. It had a 2in hole in it and by the time i got it all cleaned up and cut back the hole looked like a small potato. This one went in a stroker motor and is holding up fine.  Attached ImagesI hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Actually had 2 holes in it, one was easy tho.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:I had a 1993 chevy 2500 manual and it was the nv 4500 trans.Vantage 300 kubota ,miller 304 xmt ,lincoln ln 25 pro , ranger 305 G, plenty of other tools of the trade to make the sparks fly.
Reply:Originally Posted by weldermikeI've welded a bunch in the past, and the prep work is most of the job, I prefer them out of the vehicle, but sometimes you just you don't have the option. I just did this one not long ago. It had a 2in hole in it and by the time i got it all cleaned up and cut back the hole looked like a small potato. This one went in a stroker motor and is holding up fine.