Honda Engine Block - Cast Aluminum

[engnerdan]

I got a call last week about welding an engine block. I assumed it was cast iron but figured I would check it out. Much to my surprise it was aluminum, this hole was formed when a boss that is cast on the block got pulled away by the exhaust manifold. I was originally going to weld a plate in, but once the boss was moved out of the way I decided to just weld it up. I welded the hole shut, cleaned it up and laid a second layer on top of it.

Did this repair with my Dynasty 200, coolmate 1, 2% lanth 1/8", 150hz 72%. Total repair time from arrival to packed 2 hours.


-Dan

[Kamikaze]

NIce work!

What was you cleaning method and how did you go about getting the build up done?

[Daniel]

Nice job engnerdan.

Did you burn the grease and oil out of it before welding it?

[engnerdan]

The prep was wipe down the area with a lacquer thinner soaked rag, heat the area with propane torch, spray down the area with lacquer thinner and let dry and then heat with the propane torch once more.

I then made a first pass all around the hole with 4043, then ground that down slightly to get rid of any of the crud that had floated to the top, then I built on top of that with 4043.

-Dan