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  1. #1
    Join Date
    Nov 2013
    Posts
    7

    Default Aluminum Block Welding ?

    I need to build up an area on the rear bellhousing flange of an aluminum block (356 T6)

    I had a .875" thick piece of 6061 welded to the casting in order to machine a pad to accept a starter mount (the block originally had no provisions for an onboard starter) but the starter block ended up being 1" thick, so I need to build up this area (aprox. 6" long by 1" wide) in order to match the width of the starter block.

    I have limited experience welding aluminum, and that is on much thinner material than what I will be working with here. The machine that I have access to is a Miller Syncrowave 350, and I have just about any filler rod, tungsten grade and sizes available to me.

    I'm looking for any input as far as procedure, machine setting, filler rod, etc. to help me be successful completing the job.


    Thanks, Dave

  2. #2
    Join Date
    Nov 2003
    Posts
    3,059

    Default

    Quote Originally Posted by hotrod1442 View Post
    I need to build up an area on the rear bellhousing flange of an aluminum block (356 T6)

    I had a .875" thick piece of 6061 welded to the casting in order to machine a pad to accept a starter mount (the block originally had no provisions for an onboard starter) but the starter block ended up being 1" thick, so I need to build up this area (aprox. 6" long by 1" wide) in order to match the width of the starter block.

    I have limited experience welding aluminum, and that is on much thinner material than what I will be working with here. The machine that I have access to is a Miller Syncrowave 350, and I have just about any filler rod, tungsten grade and sizes available to me.

    I'm looking for any input as far as procedure, machine setting, filler rod, etc. to help me be successful completing the job.


    Thanks, Dave
    Best filler these days for 356 is Hobart/Maxal 4943..
    Relatively new on the market... but neat stuff..

    http://www.maxal.com/Hobart_Maxal_4943.pdf

    here is a recent thread on 4943

    http://www.millerwelds.com/resources...highlight=4943

    and if you could get use of a Dynasty 350... it would be relatively simple..

    Chris Razor does some very nice work on cast..

    here are a few videos worth watching before you start..

    http://www.youtube.com/watch?v=OUr2hMIrDfo

    http://www.youtube.com/watch?v=ohuoWdZ7fW0

    http://www.youtube.com/watch?v=N9aqMknf_0g

    http://www.youtube.com/watch?v=Oh5n9fHdGjM
    Last edited by H80N; 11-30-2013 at 03:59 PM.
    .

    *******************************************
    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 CNC Mill, Lathes & a Plasmacam..

  3. #3
    Join Date
    Nov 2003
    Posts
    3,059

    Question Aluminum DRCE Engine Block..???

    Is this the Block you are working on??

    Aluminum Olds Racing Block??

    http://www.gmpartsdirect.com/perform...ATID=1323.html
    .

    *******************************************
    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 CNC Mill, Lathes & a Plasmacam..

  4. #4
    Join Date
    Nov 2013
    Posts
    7

    Default

    Quote Originally Posted by H80N View Post
    Is this the Block you are working on??

    Aluminum Olds Racing Block??

    http://www.gmpartsdirect.com/perform...ATID=1323.html
    Yes, it is a KB Olds block

  5. #5
    Join Date
    Nov 2003
    Posts
    3,059

    Smile

    Quote Originally Posted by hotrod1442 View Post
    Yes, it is a KB Olds block
    Had a feeling that might have been the one...
    .

    *******************************************
    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 CNC Mill, Lathes & a Plasmacam..

  6. #6
    Join Date
    Nov 2003
    Posts
    3,059

    Question

    Only 87 miles from Sarnia to Chris Razor's shop in Plymouth, MI...

    you might consider having him do the welding for you..

    it is a pretty expensive block.. and you may not want to practice on it..

    just a thought..
    Last edited by H80N; 12-01-2013 at 10:06 AM.
    .

    *******************************************
    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 CNC Mill, Lathes & a Plasmacam..

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