IH truck, cracked cast iron front cover

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Owner sent truck last week for me to weld in place. Refused job told him to get another front cover, he thought the block was cracked. Mechanic came yesterday afternoon with it. Story: Priced a new one $3000, called around and could not find a used one. Years ago where I worked we bought lots of core engines and parted them out, threw a bunch of these in scrap iron bin. He said he checked there too.OA spray, 750 pre and post heat remachine and call customer to pick up. $400 for hot job.Peter Attached Images
Reply:more pics Attached Images
Reply:This is how I stay cool.Peter Attached Images
Reply:Nice job and great welding.
Reply:freaking awesome! I enjoy seeing the stuff you fix, just blows my mind sometimes.
Reply:Originally Posted by castweldOA spray, 750 pre and post heat remachine and call customer to pick up. $400 for hot job.Peter
Reply:Every time I look at one of your posts, I'm thinking controlled heating and cooling rates.I'm not quite sure what I'm exactly looking at every time, but the heat is uppermost in my mind"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by steelNice job and great welding.
Reply:That's just freakin' awesome. Beautiful repair job. Do you have an oven, or just heat with a rosebud? if it's a rosebud to you just read the color to determine temp or use one of those temp crayon things?Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Originally Posted by app-ironworksllcThat's just freakin' awesome. Beautiful repair job. Do you have an oven, or just heat with a rosebud? if it's a rosebud to you just read the color to determine temp or use one of those temp crayon things?
Reply:Well the job would have been $1000 in my book.  400 is too cheap.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:simply amazing.  so that's what those fancy pants torches with a hopper is for.  now i know.
Reply:[QUOTE=castweld;Oxygen Acetylene torch w/hopper for powdered metal.Area is prepped then heated with torch. When area reaches a dull red, lever is depressed and a small amount of powder is sprayed. The area is heated untill powder "wets out" or bonds, after this powder can be sprayed to build up.This process works in about a 200 degree window, applied too cold it will not bond, too high- pin holes will form or hotter yet will cause alloy will ball up and drop off.To apply correctly an ability to "read" colors is necessary. Wet out occurs at around 1800 degrees.Powdered metal in this case is tiny spheres of mostly nickel welding alloy covered with flux.On engine parts, depending exactly where spray is to be applied, pre and postheat is mandatoty. Thicker parts require more pre/postheat. (diesel is thicker)ThanksPeterHow you heat and cool a cast iron weldment will determine if it will be successful or not.Peter[/QUOTE]Is this the type of equipment to metal spray......"Torchweld® Hot Metal Powder Spray Kit".  Found this on a ESAB site.  Thank You for taking the time to explain.  I see I have more research to do. Very professional repair!!!!!Last edited by geezer; 08-07-2009 at 07:59 AM.Reason: Add content
Reply:That looks GREAT!Did you put a carbon or graphite rod in bolt hole before you spray welded?Thanks for the pictures!John
Reply:great work better then stock i am suresyncrowave 180 sd
Reply:great work you should make a vid on how you do it
Reply:Just be aware, Castweld,,,,   I'm assuming this is a front for a DT466, there should be huge amounts of these, available in the next couple years.   The California Air Resources Board (Carb), has essentially obsoleted any and all pre-90's  diesel truck engines, in this state, and over the next several years, in four to five year groups, will be obsoleting everything right up to the 2010 model year, by 2014.May be very well cheaper, to buy and use scrap parts, the next couple years, than to fix the original cracked parts.
Reply:Nice repair, BTW,,,,   myself,,, I haven't even changed the oil, on my 85 IHC, for two years now, why bother?????  Fresh engine, also, did an in-frame on it about 70,000 miles ago.
Reply:Brilliant Pete!I believe I do see a carbon rod in that bolt hole.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:Great repair.  I sold my powder spray torches.  I had one "hot" and 2 "cold".  Didn't use them but maybe once every 5 years.Again, great job.
Reply:Originally Posted by duaneb55Brilliant Pete!I believe I do see a carbon rod in that bolt hole.
Reply:Originally Posted by lugweldWell the job would have been $1000 in my book.  400 is too cheap.