modifying 93 accord distributor to fir 89 accord. tig aluminum

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with my turbo setp i need to have tuneability. so this means i had to upgrade my odb-0 accord to an odb-1 setup. the parts i am using are an external coil distributor from an 93 accord. i am also using a chipped/tuneable ecu from a 93 honda civic.after playing around with the different distributor for a while i finally came up with a solution today on how to mount it.this is an old spare a20a accord motor i am using for mock up for my turbo manifold. i am also mocking up my modified distirbutor.i was actually pulling this off caz i was tearing down this head to get it ready to send for port and polish. the cam cap that i am modifiying i orignally thought i would have to replace cuz i broke one of the original bolts in it. once i removed the lifter assembly so i can get the cam out i noticed that it would be esiest to modify the cam cap and not the actual distrobutor.the is the orginal cam cap. the two arms dont meet up with the new distributor so i have to cut them off and weld on new onescutting the arms off with my chopsawthis is a d16z6 (92-95 civic sohn vtec motor)cam cap i had laying around. it actually goes to a motor i was planing on rebuilding in the future. oh well, ill get another one soon. i decided to use this cuz it had pretty long legs and it had the right size threaded hole for the distributor screws. the only problem is i needed two of themme cutting the leg off this cam cap with the chop sawmy new leg to weld to the original cam capi know welding requires the parts to be really clean so i hit them with the wire brush on my bench grinder. the first pic you can compare the cleand one to a dirty onei also wire brushed the cam cap where i will be welding the legs to
Reply:here you can see the modified cap sitting on top of the new distrobutor as if they where on the motor. the leg on the left is the d16z6 one i will be usong for both sides. the one on the right i cut off a cam cap for a b18a motor, pretty much wasted it cuz it was too short. i was going to make a spacer but i rather just use another d16z6 one so i wont have 2 welded points on itthis is the new distributor sittung in the hed, you can see the bottom leg doesnot need to be modified, i just need to use the original bolt. you can also see where i have to modify the case on the left side of the distributor to make room for the waternect screwok, my question. using my syncrowave 200, what setting should i use to weld these legs? what filler rod/tungston combo? i still havent welded anything yet. also what argon sould i be using for this weld job, 100% pure or a mix?
Reply:Zap will answer that ....Me...Well I just say I love this kind of projects....guys making HPs and modifying engines...for HP´s sake =)Hope everything turns out fine... Can´t wait to see the progressMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:I have heard from buddies who have welded on honda aluminum castings that it is not fun because they are not pure aluminum, and also that they are quite porous as well. You might want to practice on some unimportant honda aluminum before you attempt to weld on your final distributor.Good luck!JeremyLast edited by jeremydde; 11-14-2006 at 11:09 AM.Miller Synchrowave 180SDLincoln WeldPak 100HD w/gas conversionPowermate 230A AC Arc Welder circa 1980
Reply:Zap will answer that
Reply:Originally Posted by zapsterAnd some will disagree but whatever...3/32 red end tungestion ground to a point..gas mix 75-25 or if ya got a mixer i like 36-38%5356 filler 1/16 dia.  ..start at 200 ampsdont be "put off" if it comes out crappy...your going to have to grind and re-weld a few times to get the crap out of the casting..do not pre-heatlet cool naturally after welding before grinding..if it cracks in places dont worry you'll be going over it enough times to make that stop..clean clean clean!!!stainless wire brush and acetone...like i said some will disagree but whatever.. have fun.. post pics and we'll get a better look as you go..maybe see something along the way to do/avoid.....zap!
Reply:Originally Posted by chopper5
Reply:good, so ican use the tank of 75/25 i have for something
Reply:Originally Posted by zapsterAnd some will disagree but whatever...3/32 red end tungestion ground to a point..gas mix 75-25 or if ya got a mixer i like 36-38%5356 filler 1/16 dia.  ..start at 200 ampsdont be "put off" if it comes out crappy...your going to have to grind and re-weld a few times to get the crap out of the casting..do not pre-heatlet cool naturally after welding before grinding..if it cracks in places dont worry you'll be going over it enough times to make that stop..clean clean clean!!!stainless wire brush and acetone...like i said some will disagree but whatever.. have fun.. post pics and we'll get a better look as you go..maybe see something along the way to do/avoid.....zap!
Reply:Originally Posted by SQ is the SQUADgood, so ican use the tank of 75/25 i have for something
Reply:geez!