When you have an aluminum weld break out right where the cap joins the barrel, do you try and clean off any of the old weld or just have at it?
Boat ran over a rock pile and pulled the cap away from the barrel.
This isn't my job but I can go help and will try to be there just for the experience and would like to know what most would do with this.
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Thread: Another Pontoon Boat
09-06-2013, 09:45 AM #1
Another Pontoon Boat
09-06-2013, 07:43 PM #2Senior Member
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If you dont grind it youll be sorry.
09-06-2013, 10:56 PM #3
09-07-2013, 06:51 AM #4
as you know... our resident Pontoon Wizard is FusionKing...
I would review his old posts on the subject.. like your old thread here...
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09-07-2013, 10:15 AM #5
I have since got the low down on 5356, tougher and durable and takes a little more heat etc.
HAZ is much more of a problem than the filler.
4043 or 5356 wouldn't matter as both will be more than stronger than the heat affected area at the welds edge where this cap came apart.
This job is not mine, its at another shop. The last job I never got to do, in fact the splash guards are still in the shop. Seems the owner isn't using the boat and has no desire to fix it yet. So I still have not welded on one of these things yet.
This post I was asking about the old weld. Would you grind it all off or just clean it good and weld back to it?
About everything else in the world I would grind/ remove all the old weld. This may cause fit up problems here. But then again, I don't have the final say.
I understand to make good welds is one thing, the knowledge and experience to prep it right is another. I'm getting to the point where most welds I look at in the world look like poop and gaining confidence that maybe I have a bit more pride in what I do than a lot of company's and individuals.
But an engineer, I am not. Knowing the best way every time, I am far far from that.
This job on the cap IMO is likely to crack open again on the trailer. The weight of the boat has it egged shaped. The boat will have to be lifted to make the joint and weld, then instant and constant stress bouncing down the road.
Like most jobs it has to be done. Good thing is it won't sink the boat if it does develop a crack. Best thing is, it won't have my name on it.
09-07-2013, 03:19 PM #6Senior Member
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09-07-2013, 07:33 PM #7
If I were doing this job I'd fit the head back on with the weld to help with positioning then I'd grind the weld out for a proper re-weld. I use some zirconium flapped disks that don't seem to affect aluminum weldability. Stainless wire brush cups on a die grinder work well then I usually follow with aluminum brightener then proceed with welding. Don't try to weld it all at once to help with distortion. I'm not Fusionking but I've had plenty of success following his advice.Dynasty 200DX "Blue Lightning"
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09-08-2013, 05:12 PM #8
Its done now, it was an ok fit up after the hammer work and no hammer marks. The weld was left on.
Just dropped down about 3 inches each time and welded up to the beginning of the previous weld. There was a 3/4 inch gap to fill at the very bottom.
It actually took two of us, I did the welding and my bud worked the peddle because it wouldn't reach. Ever try that?
It came out good, the pressure test revealed one tiny pin hole in about 18" of weld. Now I just hope it holds forever or at least until the next rock pile.
That aluminum welds really good, glad I finally got the opportunity to check it out, I'll get over the backaches soon enough.
09-08-2013, 06:35 PM #9Senior Member
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