weld cast aluminum atv engine cover

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Small casting repair, takes longer to machine than weld. Used wire brush on die grinder to clean. When I frist started welding aluminum I was told- and read that you have to use stainless brushes dedicated to al use only. I did. Then tried steel, and then tried brush used for general cleaning. Couldn't see a difference. I use same steel brushes to clean paint, rusty steel, carbon from cylinder heads, and aluminum to weld. If brush is oily or contaminated I spray carb cleaner on brush while using and this cleanes it up.This area is an edge and required no pre or post heat. Built up with 4043 untill I had more than enough to machine. Last pic is part machined. I used flap wheel on die grinder to blend after I took pic. Looked nice but sorry no pic.Peter Attached Images
Reply:Nice Job....  Looks freakin' Great !What do you like to use as far as 'shaping tools' so that you can bring something like that back to life after it's been welded ?Cheers,/Jman...Miller Diversion 165120 amp Buzz BoxVictor Oxy/Ace Oxy/LPGSmith "Little" Oxy/LPGHypertherm Powermax 30Lot's of Misc. tools n' crap....
Reply:you can use a scotchbrite pad intended to be mounted in a drill for blending also.  I get them at walmart.  They are about 5" in diameter and have a 1/4" arbor.  I run them in my die grinder.My name's not Jim....
Reply:Did you let it cool between passes?
Reply:Originally Posted by jmanNice Job....  Looks freakin' Great !ThanksWhat do you like to use as far as 'shaping tools' so that you can bring something like that back to life after it's been welded ?Cheers,/Jman...
Reply:Looks good.  I've done countless repairs along those lines.  The biggest problem I run into is JV weld repairs and poor castings.  I've never machined them afterwords.  The only steel brushes I use are large ones, so they are only used on big steel projects which dont usually get brushed anyway.  The 1 inch brushes are S.S. and I cross them between aluminum and s.s. all the time.  And if they are dripping in goo from a messy job, I just retire them and grab a new one.One scotchbrite trick I have learned is to grab a cut-off wheel arbor and sandwhich 2 pieces of new scotchbrite  on it.  I dont bother to make it round.  After a while, it will round it's self just fine.  I tried this with a 4" grinder and found they spin too fast and will blow the scotchbrite apart where as the die grinder can be controlled in rpm's. Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:Originally Posted by BrainfarthLooks good.  I've done countless repairs along those lines.  The biggest problem I run into is JV weld repairs and poor castings.  I've never machined them afterwords.  The only steel brushes I use are large ones, so they are only used on big steel projects which dont usually get brushed anyway.  The 1 inch brushes are S.S. and I cross them between aluminum and s.s. all the time.  And if they are dripping in goo from a messy job, I just retire them and grab a new one.One scotchbrite trick I have learned is to grab a cut-off wheel arbor and sandwhich 2 pieces of new scotchbrite  on it.  I dont bother to make it round.  After a while, it will round it's self just fine.  I tried this with a 4" grinder and found they spin too fast and will blow the scotchbrite apart where as the die grinder can be controlled in rpm's.
Reply:What Brainfarth posted is a homemade version of what I was talking about.  The scotchbrite under the grinder is kind of cool.My name's not Jim....
Reply:what is that case off of?
Reply:Originally Posted by 99trxriderwhat is that case off of?