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  1. #11
    Join Date
    Nov 2003
    Posts
    2,983

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    Brian
    here is an article on welding automotive aluminum cylinder heads... there is a lot of similarity between the two..

    http://www.enginebuildermag.com/Arti...num_heads.aspx

    best of luck and please keep us posted...
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
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  2. #12

    Default

    I've managed to get the extension welded onto the old intake, went pretty well. No leaks on a 40psi pressure test. I guess we'll see how it holds up.
    SAM_2795.jpgSAM_2796.jpg

  3. #13
    Join Date
    Nov 2003
    Posts
    2,983

    Default

    That is Great!!

    could you outline what you did to accomplish this with limited amperage??... preheat.. blankets etc....
    Thanks...
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus Mills, Lathes & a Rat Tail File..

  4. #14

    Default

    I preheated on my gas grill (don't tell the wife) before making the welds where the new material attached to the casting but I didn't get too crazy the thing may have been 200deg or so. I didn't maintain any heat on it while I was welding other than what the welder was putting in.

    The areas I was attaching to were about 1/4" thick with the new material being 1/8" and 1/4" the only places that were thicker where were the old bolt bosses were.

    Had the Sycrowave 180 set at about 165a and luckily didn't have any problems except for a couple of really tight inside corners where the arc was jumping all over the place....fortunately where that was happening I was able to get nice clean welds on the opposite side of the joint so no problems.

  5. #15
    Join Date
    Nov 2003
    Posts
    2,983

    Thumbs up

    Brian
    thanks!! that will give the guys with smaller machines some food for thought before they tackle aluminum castings...
    Frankly... I was concerned about your outcome.... glad you thought your way around the situation.....
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus Mills, Lathes & a Rat Tail File..

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