Welding Aluminum

[85TriZ]

has n e one ever try these Alumumin welding rods


Brazing Aluminum and repair aluminum with a propane torch

http://durafix.com/ Video

http://www.youtube.com/watch?v=rKJ_edau-qo


Just wondering if i could repair my side casing on my Tri-Z motor ?????

[Red Barron]

I f you want it done right take into a welding shop....

[85TriZ]

yaa thats what i was thinking too ,,,,,,,,,......, but i like to fix things myself

[Red Barron]

If you were in Mb I could weld it for you..:cheers:..

[85TriZ]

yaa that would of been nice ,, as there are only 1-2 places that i know if in town that could weld that for me,,(prob more places that i dont know of tho) ,,, thats why i was gonna pick up a package of them Alum, Rods and practice ,, than tackle the side case myself ,,,,,

[Outlaw]

One of the skag(outboard motor) repair shops should be able to do a decent weld on it,perhaps try some JB Weld,or some other "epoxy" type quick weld on it depending on how big/small the repair area is.Make sure you get it super clean before using anything on it.

[06ac500]

this is pritty easy to do...ie video... just practice first and remember that these rods arn't cheep... and pre heat is key...

[85TriZ]

ya OUTLAW ,, both covers had been JB welded before ,, but wont hold from the pressure of the kickstart on the one ,, so i would like to have it welded so it will be stronger and last longer ,,,

[85TriZ]

ya 06ac500 ,, i was gonna pick up a package and practice with a couple ,, than when i got good enough ,, try the covers ,,,,

[85TriZ]

http://i304.photobucket.com/albums/nn183/93jeepman/Polaris%20atv/IMG_0343.jpg

[85TriZ]

http://i304.photobucket.com/albums/nn183/93jeepman/Polaris%20atv/IMG_0342.jpg

[MudChucker]

you will want to get the super alloy #5 welding rod, (the rod in the photo is a super alloy #1 )as your going to be trying to fix a cast product (which wont care for the heat too much) you should also get a 600F to 750F degree temple stick so you can see when you have preheated enough... the super alloy #5 rod melts at 600F...evenly preheat the work before you weld it, use the temple stick so you know when your adequately preheated.... and I'd also suggest you run it through the dishwasher a few times to be sure there is no oil or paint residue in the area you are going to weld together.

[85TriZ]

well i called around ,, seems no one carrys the Alum, rods ,,(one store just sold out and dont know when they'll get more & are $10 ea for the small rods) ,,,,, so i may just take it to a shop and have them do it ,,

[MudChucker]

Order from these guys...

http://www.muggyweld.com/international.html

[MudChucker]

if you do order from muggyweld, then you wont need a temple stick, just get some of their flux as well... its a powder product that will liquefy at the optimal time to apply the filler metal...

[LeCaptain]

if you do order from muggyweld, then you wont need a temple stick, just get some of their flux as well... its a powder product that will liquefy at the optimal time to apply the filler metal...

If flux is the same as used for electronics, it is used to clean the joint. When heated, it turns into acid thus creating a clean surface to bond to.

[MudChucker]

If flux is the same as used for electronics, it is used to clean the joint. When heated, it turns into acid thus creating a clean surface to bond to.


exactly...

their fluxing agent has an additional property in that it designed to only melt at the exact temp the rod it is designed to melt at...this prevents the fluxxing agent from melting and running all over the work piece long before the metal is preheated enough to form a bond.

if you buy the rods from them, the fluxxing powder will ship with the rods in a kit... you dip the rod into the powder...

[85TriZ]

well i wonder if there the same ones i see on ebay ??? there a crap load on there cheap ,,, 20 packs for $11 + $3 shipping !!!!!! 10 packs are even cheaper ,,, UltraFuse ,,, think i may bid on them ones ????

[MudChucker]

well i wonder if there the same ones i see on ebay ??? there a crap load on there cheap ,,, 20 packs for $11 + $3 shipping !!!!!! 10 packs are even cheaper ,,, UltraFuse ,,, think i may bid on them ones ????

I havent tried those... looking at the feedback of the seller they may likley do a good enough job.

[straight-pipe]

MC....how many hours or minutes of welding experience do you have with aluminum? Do you have any pics of work that you've done?

[85TriZ]

yaa MUDCHUCKER ,, i also checked out the feedback to see if there was n e neg's about them ,, but there wasn't ,, soo i bought a 20 pack ,, sooo i'll know in about 2 wks what there like ,,,

[straight-pipe]

Dude you have no idea what you are up against. Welding aluminum is wayyy different than welding new mild steel. I have experience welding aluminum when I was working in WPG fixing highway tractors for brothers autobody down by teasers and also at my new job at a local machine/manufacturing shop and I was taught to weld by Ian's father (the late Phil Hiker). I had an issue with my 03 500 cat where the case needed welding as well and my issue wasn't as severe as yours and I brought mine to a reputable shop who has an outstanding tig welder. This video was probably done by a professional and that is who you should bring your case too as well. Might cost you 100 bucks to get it done but I fear if you do it yourself you might as well start looking for another case.

[85TriZ]

yaa it looks real easy ,,, heat the Alum, start rubbing the Rod over it til it melts out over ,,, but that could be a whole dif story when i go to try it ,,, i got 2 cases and if i mess one up ,, i will be taking the other one to a professional and getting it done right ,,,
I'll post pics of my work when i get the rods and do it ,,, give u guys a good laugh maybe ,,,,,,

[straight-pipe]

giver man! good luck.

[ian.]

if it is a good grade cast al it should be weldadble (tig), cheap casting are real porous and can be very difficult to weld.

[MudChucker]

should mention, there is a huge difference between fusing the metals as you would be tig or mig welding and "brazing" with these rods and using these rods to "glue" the parts together... this is really more like soldering then welding... the porosity of the base metal isn't such a big deal as your not taking the base metal to its melting point, but you do have to worry about cracking the base metal from rapid/over heating or uneven heating...

I bought a 20 pack of these rods...and I've fixed a hole in a rim (that I later touched up with the mig and some 5356 as the repair over the hole itself was too thin) and melted the rest welding an aluminum valve cover back together for a friend of mine...the valve cover is still holding together...

these rods really are as easy to use as the video shows... just be sure and preheat the part till the fluxxing agent melts, preheat your rod till it starts to go soft, dip the rod in the fluxxing powder and start working the rod over the seam... the hard part is keeping everything in alignment as you stick the parts together... be prepared to waste a rod or 2...

[GrizzleyPeg]

Keep in mind that the cover you experiment on with the brazing rod will likely no longer be a candidate for later repair by a professional using tig. The brazing rod will be a contaminent to the tig welding process and will likely render it unrepairable by tig later.

Do yourself a favor and get yourself a quote on repair by tig. They can likely fix it as good as new. I'm assuming the part broke because its subject to some stress. Tig welding will be superior to holding up after the repair. Don't let anyone who isn't experience with repairing cast attempt a repair on the part. It takes the right equipment and considerable skill to do a good job.

[MudChucker]

Keep in mind that the cover you experiment on with the brazing rod will likely no longer be a candidate for later repair by a professional using tig. The brazing rod will be a contaminent to the tig welding process and will likely render it unrepairable by tig later.

Do yourself a favor and get yourself a quote on repair by tig. They can likely fix it as good as new. I'm assuming the part broke because its subject to some stress. Tig welding will be superior to holding up after the repair. Don't let anyone who isn't experience with repairing cast attempt a repair on the part. It takes the right equipment and considerable skill to do a good job.


Cheers.. yes good advice... if you do have the budget, or even if you dont, you really should take it to a reputable shop first and see what it might cost to get it tig welded by a pro... while you did say that you have a spare (you did say that some place didnt you ?)then I suppose its a cool idea to give it a try... nothing wrong with fuxxoring something up in the name of edumacation... but if budget is a concern, it may cost you less to get it done by a pro then doing it yourself and fuxxing it up and having to go buy a new cover...

[LeCaptain]

Keep in mind that the cover you experiment on with the brazing rod will likely no longer be a candidate for later repair by a professional using tig. The brazing rod will be a contaminent to the tig welding process and will likely render it unrepairable by tig later.

Do yourself a favor and get yourself a quote on repair by tig. They can likely fix it as good as new. I'm assuming the part broke because its subject to some stress. Tig welding will be superior to holding up after the repair. Don't let anyone who isn't experience with repairing cast attempt a repair on the part. It takes the right equipment and considerable skill to do a good job.

I agree fully. Pay the extra couple of bucks and get it done right by a pro. This is what they for a living so you knwo the job SHOULD be done correctly. They should have a ton of experience under their belts.

[85TriZ]

yaaaa u guys are prob right ,,, SHOULD take both covers and get it done prof ,, than i know it'll be done right and i'll have 2 covers ,,,,, doing it myself ,i could F them up ,,, and have nothing to put back together ,, LOL ,,,,, since i got the Rods ordered and on there way ,, i may practice and try the One cover and see what happens ,,,,

[Got Mud]

Well buddy I have welded a few things made of Aluminum in my 11 years working at Lund Boats and if you have not welded Aluminum take it to sombody that can because I'm sur I have even spelled it wrong a couple of times that is how easy it is to wreeck something when you do not know how to do it. Welding steel is not even close. to the same,

[85TriZ]

HEY GUYS,, got the rods today,did a couple practice welds than hit the side cover , Not real pretty look'n but seems to hold up pretty good ,, i've hit it with a hammer and never broke ,,,,,,,,, grind & filed it down & started putting motor all back together this evening :) ,,

http://i304.photobucket.com/albums/nn183/93jeepman/Polaris%20atv/IMG_0289.jpghttp://i304.photobucket.com/albums/nn183/93jeepman/Polaris%20atv/Alumweldrods.jpg

[camoman]

Right on man, good on ya for trying it!

never learn if you don't try!

[GrizzleyPeg]

Congrats. Hope it works well for you.

[Predator_Hunter]

not bad !! ive seen alot worse.. good for you :cheers:

[85TriZ]

yaa i think it will GrizzleyPeg ,,,,,,, the other rods i was practicing with seems to be as hard as a rock ,, nooo way could i break it ,,, Files hard too !!!! had to hit it with a grinder than do the fine work with the file ,, but was slow going ,,,,,,,,, soo if it holds to the side cover it should be ok for a while ,,,,

[straight-pipe]

Hmpf! well there ya go. keep us posted as to how long this lasts.

[85TriZ]

ok will do Straight-pipe ,, i got motor all back in ,, just awaiting on Swing-Arm parts so i can start driving her again !!!