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  1. #1
    Join Date
    May 2008
    Location
    Mpls, MN
    Posts
    464

    Default Honda Engine Block - Cast Aluminum

    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
    Attached Images Attached Images
    Owner
    DW Metalworks LLC
    Miller Trailblazer 302
    Miller 8RC Feeder
    Miller Passport Plus
    Miller Dynasty 200 DX W/Coolmate 1
    Hobart Handler 135
    Hypertherm PowerMAX 30
    Smith O/A Torch Set
    Plus more tools then my wife will ever know about....

  2. #2
    Join Date
    Dec 2009
    Location
    Northern California
    Posts
    179

    Default

    NIce work!

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

  3. #3
    Join Date
    Dec 2009
    Location
    Williams Lake, British Columbia
    Posts
    722

    Default

    Nice job engnerdan.

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

  4. #4
    Join Date
    May 2008
    Location
    Mpls, MN
    Posts
    464

    Default

    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
    Owner
    DW Metalworks LLC
    Miller Trailblazer 302
    Miller 8RC Feeder
    Miller Passport Plus
    Miller Dynasty 200 DX W/Coolmate 1
    Hobart Handler 135
    Hypertherm PowerMAX 30
    Smith O/A Torch Set
    Plus more tools then my wife will ever know about....

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