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  1. #1
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    Nov 2013
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    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
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    3,264

    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 04:59 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
    3,264

    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
    3,264

    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
    3,264

    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 11:06 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..

  7. #7
    Join Date
    Nov 2013
    Posts
    7

    Default

    Quote Originally Posted by H80N View Post
    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..
    I kinda wanted to give it a whirl myself..........you don't learn if you don't try mentality

    But your probably right,.... Man, after watching those YouTube clips, those inverter Dynasty machines are incredible (able to weld thick sections, to thin, without preheat to the heavy area)

    And yes, Chris Razor OBVIOUSLY has the skills to do the job correctly!

    Well, I also have a set of Magnesium valve covers that need some corners added to them..........I definitely wouldn't attempt that job myself, so maybe I'll kill two birds with one stone and take them down with the block.

    Thanks, Dave

  8. #8
    Join Date
    Nov 2003
    Posts
    3,264

    Smile

    TIG welding with a Dynasty is a whole new world..

    They're not your Daddy's Syncrowave..

    If you would like to see some real magic... take a look at John Marcella's work..

    this is from another old thread

    Quote Originally Posted by H80N View Post
    There are some guys that have brought sheet metal manifolds to an artform..

    John Marcella is one of them... his work is just beautiful..

    Here are some videos...

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

    http://www.youtube.com/watch?v=Db6BVMANvW0

    Here is the link to his website... lots of pics

    http://marcellamanifolds.net/images/Images.html

    (And yes I realize it is an old thread..and that some have seen this work.. but it is so nice... it may serve as an example of the art...)
    Last edited by H80N; 12-01-2013 at 01:56 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..

  9. #9
    Join Date
    Nov 2013
    Posts
    7

    Default

    Quote Originally Posted by H80N View Post
    TIG welding with a Dynasty is a whole new world..

    They're not your Daddy's Syncrowave..

    If you would like to see some real magic... take a look at John Marcella's work..

    this is from another old thread
    Yes, I've seen his work..........he has some SERIOUS Tig welding skills!

    His stuff is total perfection! Pieces of art...... under the hoods of race cars

  10. #10
    Join Date
    Nov 2013
    Posts
    7

    Default

    H80N,

    Sent you a PM

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