Thanks AK, Jonathan, Oscar, Matt, Steve, Arno. Can't tell ya how much I appreciate your input. This forum is stocked with some people of character and is a great resource for wanna-be welders like me. The guys are pulling that engine. We will get a better look at the damage soon. The hole is for an ...

Hello friends, Haven't been around lately. Leave it to an old friend to come around only when he needs something. ;) We have a cast iron engine block with a threaded bolt hole. Half of the surrounding iron is broken off. The broken piece is long gone. My first thought was to build up a new boss arou...

Definitely a 300 game

welcome to the forum. Curious. is this an engine crankshaft bearing? Why patch and not replace?

It appears that if the welds are splitting and the tubing is staying intact, not even bending..... The frame may stand to lose some weight. Also, crumple zones are designed to collapse not break. How do you design the front end of a car to absorb the impact and not bounce off the wall. It would seem...

rsears. It was right to call me out on my careless judgement of your friends driving skills. Will you please forgive me? Relating to people I'm often like a piece of aluminum caught in the Cross-fire of electrons of a tig torch. As the current and subsequent heat go up there is a cleaning effect. So...

thanks for the tip on prepping the cracked casting. now I understand why the piece was so distorted. It must have been overheated. Next time I will drill more and groove less. Also, I will change the technique to accomplish a cleaner, cooler weld. And that "bubblin' crude" could be machine...

Hi, Didn't get the advice soon enough. I understand now how grinding off the weld would have helped. The trans fluid percolated up into the puddle. It was hard to know when to dab the filler (5356) because of the corruption. The crack was grooved and rinsed with plenty of acetone. I did the inside w...

My Fellows, Wish I had more time to think thru this cast alloy trans pan repair. Can you help me? It needs to be welded overnight tonight. The pan supports an exhaust manifold bracket. The failure was due to heavy-handedness on the part of a young tech. (did ya see the timing cover repair?) Been the...

no expert here either. But it does look as though there was too much downward force on the pedal toward the center line of the car and not enough force on the pedal next to it.
was the tubing cold when it was welded and did it cool to rapidly?
Don

The resources this forum provides are indispensable. All you folks are helpful and entertaining. :) The head was removed. The stainless steel exhaust manifold stud was removed by welding a nut to the broken end. 309 filler was used at 80 amps average. Here are the pis of the fix: http://i948.photobu...

Thanks for the suggestions. When I told the Service Advisor I needed time to practice welding with a mirror, suddenly removal of the cylinder head became cost effective. I'll remove that broken stud in that head on my bench at home.
Don

hello friends. I need to weld something I can only see with a mirror. It's a broken stud in an aluminum cylinder head. I have done this procedure before on the bench. Removal of the cylinder head is not cost-effective at this time. I'm pretty dyslexic so it shouldn't be any problem. ;) . http://i948...

Dewd, your instructor must have a lot of confidence in you. here's a pop quiz for you: is the block still in the car? will it be subject to the same stress that broke it? engine blocks are thick. Do you have the amps? have you walked through the project in your mind thoroughly? are there areas on th...

quote]"I used a dummy bolt and sandwiched the broken section of the timing cover with 2 washers. This allowed me to keep the bolt centering "[quote. In a previous post I did say I used washers. Sorry to have mislead you Steve. Good suggestion to use anti-seize also. Another thing I did was...

here's the bolt using flanged nuts. (not washers as previously stated)Not pretty eh?

Hello and thanks for the compliments. This was one of those occasions when it was possible to help some people out. The cost to replace that timing cover may have exceeded the value of the vehicle. (a very corroded 2001 CLK 320). WT&T is a most valuable resource. The thoughtful people who subscr...

Thanks again for the suggestions. I will grind a little on the broken piece to see if it's 53xx. That piece will be fitted with a bolt shank minus the treads and plating. Practice passes will be made experimentally on the piece. The intent is to close the aluminum around the steel bolt in practice. ...

thank you for the suggestions. I thought I would ground the negative electrode on the block.I've been told that disconnecting the negative battery cable should be good enough to protect electronics. Thanks for the reminder to clean off that oxidation. it's good to see someone resurrecting those old ...

Thanks for the suggestions on the copper and the ID method Steve.

Hi Fellows, I need to repair a cast alloy timing cover on the engine and in the car. Rather than attempt to weld the broken piece back on the cover I thought it would be best to insert a copper tube in the bolt hole. I would then fill the void around the tubing by building up material with up a numb...

Hi, I'm a workaholic grandpa who should know when to retire but won't. Fixing things is almost the most gratifying activity I can think of. Hope to contribute my 2 "sense" worth.