welding cast aluminum intake manifold help

admin

I just got my everlast 256 and i figured i would put it to the test this eve. I've never had good luck welding cast aluminum before, and this time was no different. I have all he power i need now but its seems so dirty bead looks like crap really. I had the ac balance set to as far as the 3/32 tungsten could handle. Really peppered looking. anybody that might have some pointers on cast stuff id really appreciate it. mainly filling holes from smog equipment fixing cracks etc. Oh BTW i sandblasted the intake then i took a carbide burr and cleaned up the holes to be filled and dug out the crack i had to fix.
Reply:Some parts can be cleaned with brake cleaner and outgassed in an oven. Usually you'll need to run the torch over the weld area, it'll boil out a bunch of ****, then brush, and repeat, then add some filler and brush and repeat. You can usually get a clean base to work with doing this. Also be careful running more EP cleaning than is really necessary, it's an easy mistake to make.Last edited by MikeGyver; 07-29-2011 at 03:22 AM.Welding/Fab Pics: www.UtahWeld.com
Reply:Yea i learned fast DONT turn the ac balance up cause your tungsten goes up in smoke!
Reply:There really is no good way to make cast clean. It has a lot of pockets and inclusions from the casting process and all that crap boils to the surface when you put the torch on it. The best thing Ive found is to clean like you described then run the torch over it to smoke and boil the junk out of the joint and brush it clean till you get a reasonably clean joint that can be welded nicely. Some are worse than others, obviously anything sand cast(intakes) will be dirtier than die-cast(pistons and such)
Reply:Using brake cleaner esp on cast that is full of pockets is a great way to KILL yourself..   just one pore of residual brake cleaner is enough to produce the 6 parts per million of this chemical weapon (Mustard Gas aka Phosgene gas) to be harmful if not fatal.   Everyone who uses or suggest using brake cleaner should be drug out and beat with the stupid stick...Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Originally Posted by soutthpawUsing brake cleaner esp on cast that is full of pockets is a great way to KILL yourself..   just one pore of residual brake cleaner is enough to produce the 6 parts per million of this chemical weapon (Mustard Gas aka Phosgene gas) to be harmful if not fatal.   Everyone who uses or suggest using brake cleaner should be drug out and beat with the stupid stick...
Reply:unfortunately common sense is in short supply as you can see from some of the posts on this and other websites.   "I don't know what I am doing, I want to build a trailer" etc...Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:I have done lots of cast intakes..Some are better than others.You need to just use the carbide burr with some wax on it and grind out all the bad stuff that floats to the surface of the puddle..Over and over and over and over again if needed..Sometimes it seems like it will never go away but eventually it will..It can be a real pain in the rear at times..Just wait until you get asked to fix a aluminum water intake tube that has been used in salt water..You 'aint seen nothing yet.Here is one that I did awhile ago..http://weldingweb.com/vbb/showthread.php...ht=Holy+intake...zap!Last edited by zapster; 07-29-2011 at 04:12 PM.I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by soutthpawunfortunately common sense is in short supply as you can see from some of the posts on this and other websites.   "I don't know what I am doing, I want to build a trailer" etc...
Reply:Yup, Zapster nailed it. Grind and float untill your weld turns out the way it should.
Reply:I'm gonna try that next time i gotta do some cast aluminum thanks fellas really appreciate it! I'm glad im not the only one that thought cast welded like ****!!!!