Weld cracked cast al 1197 cid Waukesha pan

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New customer sent busted pan to weld. When gouging crack I found area with some serious porosity. This was about at midpoint, I suspect is the reason for crack. I ground area untill there was an acceptable ammount of pits. Cut patch, then bolted steel strong back to reduce warping pan rail from welding.Preheat to 525 degrees to burn oil into ash, lowered temp to 350, removed from oven and welded both sides, post heat 350 for 30mins, cool slowlytig-4043 fillerGround weld flush and used needle scaler to texture weld area.This was one of the most porus castings I have welded, oil gets in pores and all the cleaning in the world will not get it out. You are welding away and puddle opens pit full of oil- oh what a mess when arc hits oil! Clean that mess and start over and this happens over and over. Makes me wander why I do this.Peter Attached Images
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Reply:Man!  That was some nasty porosity.  You're truely a magician Peter.  Nice finish job too.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:MAN,...  I don't know how you SLEEP at night with all that 'HORRIBLE' work you do!!  Cheers,/Joe...Miller Diversion 165120 amp Buzz BoxVictor Oxy/Ace Oxy/LPGSmith "Little" Oxy/LPGHypertherm Powermax 30Lot's of Misc. tools n' crap....
Reply:Nice Job. I did't think there were any any of those old 1197's around anymore, must be 20 years since I played with one.You couldn't afford to start one now, let alone move it at $3.00 gal for gas.   Bill
Reply:Beautiful job----again....
Reply:That's inspiring work. Thanks buddy
Reply:Originally Posted by duaneb55Man!  That was some nasty porosity.  You're truely a magician Peter.  Nice finish job too.
Reply:Peter--excellent work as usual!--Presumably you inspected flange flatness, prior to, then after welding??(I check flatness in front of the customer-prior to work, then after--with appropriatediscussion about what it's going to take to re-face/seal the flange, if warpage is found.) --Then used a bolted strong back to help maintain flatness over the break area,before pre-heat, during welding and after. Others should take note of this strong back procedure, especially if using oven heating.Here's a man who understands that aluminum, especially castings, likes to movearound in ways to screw up a job.Blackbird
Reply:Excellent work! That takes real talent to do an oil pan succesfully first try! We have these 2 C level welders (Im in mechanics college) who made an oil pan for a chevy vega project car at college, and I kid you not, it took them about 4-5 tries to weld the pan so it didn't leak. We started calling it the "Swiss" (like the cheese) oil pan because of how many leaks there were. After they made it leak-free it took them a few days with the oxy-acet. torch to heat up the pan and warp it back into proper place! Just a quick story on what can happen with oil pans!
Reply:Wow that was a horrible casting for sure.    and a damn nice repair when all was said and done.    On a crack like that i have been known to just run a pass with no filler down both sides of the crack after a stop drilling the ends.  seems to bake the nasty out of the edges before you apply filler and fix the crack.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by dave powelsonPeter--excellent work as usual!--Presumably you inspected flange flatness, prior to, then after welding??(I check flatness in front of the customer-prior to work, then after--with appropriatediscussion about what it's going to take to re-face/seal the flange, if warpage is found.) --Then used a bolted strong back to help maintain flatness over the break area,before pre-heat, during welding and after. Others should take note of this strong back procedure, especially if using oven heating.Here's a man who understands that aluminum, especially castings, likes to movearound in ways to screw up a job.
Reply:Originally Posted by Slag Trap StuExcellent work! That takes real talent to do an oil pan succesfully first try! We have these 2 C level welders (Im in mechanics college) who made an oil pan for a chevy vega project car at college, and I kid you not, it took them about 4-5 tries to weld the pan so it didn't leak. We started calling it the "Swiss" (like the cheese) oil pan because of how many leaks there were. After they made it leak-free it took them a few days with the oxy-acet. torch to heat up the pan and warp it back into proper place! Just a quick story on what can happen with oil pans!