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  1. #1
    Join Date
    May 2011

    Default Repair cracked Sportster engine case?

    Does anyone have a filler rod suggestion for welding on a Sportster engine case? Would 4047 be the best material? Thanks, Terry

  2. #2
    Join Date
    Sep 2005
    Salem ,Ohio


    I weld them all the time with 4043 wire...Bob
    Bob Wright, Grandson of Tee Nee Boat Trailer Founder
    Metal Master Fab Salem, Oh 44460
    Birthplace of the Silver & Deming Drill
    1999 MM185 w/185 Spoolgun,1986 Thunderbolt AC/DC
    Spool Gun conversion. How To Do It. Below.

  3. #3
    Join Date
    Mar 2011


    I've done one with 4043
    Miller Trailblazer's ( 2 )...MillerBobcat 250...Millermatic 251's ( 2 )...Miller Syncrowave 200...Miller Syncrowave 180SD...Miller 12VS Suitcases ( 2 )... Hobart Hefty CC/CV Suitcases ( 2 )...Miller 30A Spool Guns ( 2 )...Miller WC 15A Control boxes ( 2 )...Thermo Dynamics Cutmaster 50 Plasma Cutters ( 2 )...Thermo Arc Hi Freq Units ( 2 )...Smith / Victor O/A Sets...DeWalt Power Tools...Craftsman / Snap On Hand Tools... Two Dodge Mobile Rigs

  4. #4
    Join Date
    May 2011

    Default The broken casting

    Thanks AAMETALMASTER & Old Skool for the tip on 4043. I'm brand new to the forum. I sure do appreciate your feedback!

    Here's a picture of what I'm trying to repair. Unfortunately I do not have the missing section of the case/motor mount that cracked off. I planning to clean up the break with a large holesaw to give me a clean circular edge, then TIG weld in a new circular piece of aluminum billet (6061) that will match the radius. Any opinions?
    Attached Images Attached Images

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