Thats true that the longevity of the part goes down with thin wall, but dosent effect the torsional stiffness much. Not problem @ racing (cars.. bikes..)

Wall thikness dosent efect on the strenght of the pipe, only material and outside diameter. You can apply the same force in pipe or axle... until there is a litle dent in the pipe. i have made controllarms for race cars with 0.8mm wall thikness pipe, material 4130. Worked great. Cant take any dents,...

http://i1236.photobucket.com/albums/ff458/VooDoo_capri/alumiinihommat/Audi/20160914_174115.jpg http://i1236.photobucket.com/albums/ff458/VooDoo_capri/alumiinihommat/Audi/20160914_174059.jpg http://i1236.photobucket.com/albums/ff458/VooDoo_capri/alumiinihommat/Audi/20160914_171750.jpg http://i1236.p...

The "step" (in reality its trumpet style step, no sharp corner) is there to slow the exhaust gas down. as the exhaust gas is comming out of the cyl head, it dosent have the inertia to change direction to flow back to cyl head. ..Thats the theory anyhow. ....and make room for the bolts :mrg...

Otherside header tacked up

Approx 5hours of sawing and tacking the pipes.
Pipes were pre bend to J shape. Lenght of the pipes is in 15mm of eachother. Looks goofy, but the lenght is far more important than looks.....and that was the easy side. Other side takes like 5hours for just 1 pipe (1 pipe is tacked up...)

More pics http://s1236.photobucket.com/user/VooDo ... 0pakosarja

I use 4047 filler on all al castings, many cyl heads etc.

BUT does anyone have experience on 4047 vs 4643 vs 4943 ? Cant get 4943 here in finland from our local suppliers. Need to order overseas if 4643 is better match on most castings

2200i dc OR acdc machine? what panel? Ta33 or ta34? http://manuals.esab.com/Templates/T119.asp?id=85038&action=frameset Here you will find manuals, for the machine and panels. Setting up welder will be in the panel manual. Find right machine/panel, copypaste number to "enter file name"...

PS series are "multifunction" powersources. FU-10,FU20. FU-30 feeder and you have mig/mag machine, TU10,TU20 and you have DC tig, And wu10 is the watercooler. And parts / service contact HR-service in finland. http://www.hrservice.fi/contact.php They might have "addons" for that ...

i'we used 4047 filler for all automotive cast alum parts. Just welded a tricky lotus omega cyl head.. it was pretty tricky job. One combustion chamber was cracked in 6 places, rest just in 4-2... pretty crack sensitive head. opended the cracks till there was no crack (check with crc red dye penetran...

How long postheat? hour?

Well.. we did make a copper backing and worked great. BUT there is a another broblem.. Its pretty rare cylinderhead that im working on and its CRACK SENSITIVE.. tried to weld some more after part was ~only 100c temp.. Crakked after welding. It was like "stopping the weld.. ping-ping-crack"...

made maaaany oilpan fixes.. Drill end off the crack, v-goove out with coarse carbide burr. Preheat to ~150celsius then last wipe with stainless brush, weld with 4047 filler.

Always worked for me.


Japan cast alum parts are allmost always nice stuff to weld.

4047 filler.. Done gooooood in past. No problems ever.


I think the brass or stainless would be way to go? bronze may couse problems... zinc boiling?

Lotus omega cyl head. SOmeone allready did use the helicoils.. And they are gone too. SO the hole is **ked up.

ANd there is some cracks in the combcustion chamber, so welding will be needed.

Well.. I need to do aluminum buildup (weld some holes shut, then drill and tap - sparkplug holes) BUT what is the best material? Besides copper, dont have copper.. BUT bronze? Brass? Stainless? Mild steel? It will have 28mm wide and 100mm long "axle" in the sparkplug hole, so there is &quo...

Just got myself Esab heliarc 283i, Incredible how smoooth arc it has, only test"drived" it for 1 night, but it feels so differend to my old "ims" chinese mahcine, MUCH better arc. And the Max output at 100% duty cycle, A 280 is a nice bonus.. http://forum.weldingtipsandtricks.com...

i might try one size bigger fillerrod to help "cool" down the budle down while welding, i find it helpful if there is gaps. Small gap = small filler = nice looking. Big gap - too small filler = hard to make it look like there was no gap

....my daywork is at local welding / industry suply shop..


We sell esab machines and consumables.


Some places sell it by the name of "alsi12" (88% aluminum 12%silicone)

i have done toyota, honda, ford, opel(gm) vauxhall (gm) saab, fiat oil pans and some cosworth cylinder heads, all done with 4047. I like to preheat 150-400celsius, preheat burns off oil and contaminants, helps alot. But the "thing" in my mind is the 4047 fillerrod, wets in so nice and can ...

http://www.cebora.it/art_364_presentazione_prod_uk.html

Made by cebora, pretty ok italian welder. i would say its something like 2000-2500bucks new

if there is room for testing, i might try 4047 filler, works great for casting repairs. And groove out the weld, then at least 2 passes over.

has anyone tested out the EVERLAST 320 EXT yet? Its on the market but i cant find any specs from everslasts page?



Edit: found the specs, pretty impressive for the price

wash with degreaser 1-2 times, wash with acetone 1 time and then heat up the whole part with BIG propane torch. It will sweat and burn most of the oil and welds SO much nicer. The time you use in prepping the welds will not go to waist, its time saved from the "weld" time and the fix looks...