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  1. #1
    Join Date
    Jan 2008
    Posts
    18

    Default Aluminum Welding Question

    I will be welding 6061 fuel injector bungs onto a cast aluminum intake manifold.

    Are there any tricks in doing this?

    I have not tried something like this, nor have i done much aluminum welding. I am working on getting a BUNCH of stuff to practice on. Do have a few extra cast aluminum manifolds to practice on, just need to get some material to weld to it.

    Thank you for your input.
    Scott

    EDIT: will be using a tig welder. 4043 filler rod work ok for this? It seems to be the most common filler rod out there.
    Last edited by Sroufe7; 01-20-2008 at 12:52 PM.

  2. #2
    Join Date
    Jan 2008
    Posts
    18

    Default

    no one is willing to give me some tips?

    I have practiced quite a bit. Welding 2 brand new pieces of aluminum together and getting the hang of it. I do have a few spare/junk cast manifolds I can practice on, which will be next thing i do.

  3. #3
    Join Date
    Jan 2008
    Location
    Most likely in Florida
    Posts
    111

    Default

    I can't help you as I have never welded anything, however auto projects is what is leading me to want to learn. I'm curious what car the manifold is for and which welder you are using?

  4. #4

    Default

    I would suggest you do a search in this forum for aluminum welding as there is a plethora of information already posted.
    It may get you more response if you post what machine, gas, polarity etc. that you are using.
    It sounds like you already have some knowledge of the process if you are practicing. Maybe some pictures of your efforts if you have that capability.

  5. #5
    Join Date
    Jan 2008
    Posts
    18

    Default

    Using a Miller Dialarc HP-F, 250 amp watercooled torch, 100% argon (is there any other gas you would use with a tig welder), 4043 filler rod.

    I have searched, but didn't find much on the subject of welding to an automotive manifold before.

    I am working on doing an 8 injector setup for a dodge avenger.

    I need to weld 4 fuel injector bungs into the lower intake manifold. These injectors only are used while under boost, this vehicle is turbo charged.

    I will post up my last welds a little later once I go back out in the shop.

    Thanks
    Scott

  6. #6
    Join Date
    Mar 2007
    Posts
    132

    Default

    Without seeing your setup, I would have a step on the OD of your bungs...that way they would drop in the holes in the manifold and you could weld around the perimeter. Sort of a positive locator for them.

    I'd practice a few on a spare manifold and see what happens.

    I'd say the intake runners are about 1/8" wall...I'd start with 170-180 amps and go from there.

    Make sure everything is very clean, tack and go.

    Good luck, and I'l like to see pics.

    -James

  7. #7
    Join Date
    Jan 2008
    Posts
    18

    Default





    First i lap welded the 2 pieces together, then I welded the top piece standing straight up.

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