Rob’s weather vane repair

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My friend and customer Rob had a broken Aluminum casting on a weather vane. It is very old and has sentimental value. He asked me to repair it. The task was to remove the broken screws in the top and to repair the legs.  It was a clean break so I decided to screw the pieces together instead of welding it. This method would also preserve the shape and finish of the original casting.1. Broken weather vane casting

2. Preheat CastingI blackened the casting with a reducing flame using an oxyacetylene torch, then heated the casting with a rosebud with a neutral flame until the soot burned off. I was then able to remove the studs.

3. Re-tapping 10-24 threads

4. Tap drilling the base starting from the cracked surface.

5. Tap drilling the leg starting from the base.

Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP
Reply:6. Tapping the leg with a 10-32 thread

7. Counterboring the hole with for a socket head screw.

8. I turning the head of a pan head screw to match the diameter of a socket head screw

9. Notice that the head is below the surface.

10. Here it is all done.

You can hardly see the cracks in the legs.-DonSmith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP
Reply:That came out great.
Reply:Very nice repair.What is the purpose of sooting the surface with the torch?Did you use anti-seize so the next guy has an easier repair?
Reply:

Originally Posted by Bob

That came out great.
Reply:Looks good. I might have sealed the bottom joints with epoxy (or even anti-seize, if also used on the screws) to keep water out and prevent future corrosion there. What happens to the top screw holes? Something again get mounted there, or are they unused? If the latter, I might have filled w/ beeswax (or epoxy, if used elsewhere).Were you told the history of the part? Why its sentimental value?
Reply:

Originally Posted by Oldiron2

What happens to the top screw holes? Something again get mounted there, or are they unused?
Reply:Great work. I always enjoy your posts.
Reply:Real nice job,  when I see broke things I wanna weld it...  You've shown some new ideas, thanks!It seemed like a good idea at the time!