Detailed Cast Aluminum Welding
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- Опубліковано 20 лип 2023
- Follow along style with no fancy editing. Just a straight up vid filling two holes in a cast aluminum part. One hole gets filled with filler, the other hole gets plugged with a slug and filled. There's also super clean arc shots that show every detail.
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Now this is UA-cam, every UA-camr should follow your lead. Straight and to the point without God dam annoying background noises that some call "music".
Arc view is exceptional! Appreciate the time you put in to get them looking so good.
Look @100amper. That is exceptional.)
Thanks for posting this despite the heat! I really like the way you just jump into the work and discuss cost.
Thank you for doing these kinds of videos. I know the views are a lot less on these niche topics, but the content is soooo valuable for many of us.
Do not hope, i always enjoy watching your videos, although i do about 5 minutes of welding per year! Still, that does not stop me from hoarding 6 or more welders through the shop collecting dust.
Those arc shots are something else man! Feels like being there and doing that ! Great stuff
:D I always find it pleasing when the needed part is found in the pile(s) of off-cuts/scraps/by-products from other projects.
Nice really appreciate you taking the time and effort for these videos!
I appreciate the videos. As I’m starting to learn just as a hobby in my garage they have really helped.
Awesome video - you just gave me flashbacks to welding a bunch of huge holes in my buddies aluminum boat. It was exactly like this except I am still a beginner, so I had to learn the circling and flooding technique you demonstrate here as I went along, and the boat had 5x more contamination and junk in it. Felt very proud that I was able to fix it though and its still floating!
Thank you so much for such an excellent video! Massive appreciation for the time and effort to share your knowledge. Knowledge shared is knowledge doubled!
Well done on the content and filming. Could see what you did and the difference between the two ways of working in the metal. Thanks for sharing. Look forward to seeing you soon. 👍
Thanks! Love watching that metal flow!
Excellent Arc Shots!!!
There is always something to learn from your videos, Thank You.
Well done Justin … love your passion for teaching
In case I have not thanked you Justin, THANKS! Been watching your channel for a few years now, listening and then applying what you teach to my hobby level TIG work. It is slowly sinking in and I just welded my first cast aluminum. A set of engine cases someone destroyed, they are very dirty castings but your techniques worked and I am pretty proud of what I have done. Still trying to learn to run a nice bead though, I am trying to build a small gas tank for a custom scoot I am building.
Try Kevlar gloves, been using them for over 20 years on aluminium and stainless steel, they work amazing, rarely get burnt...and the filler rod glides through nicely when feeding.
We love you Justin! Do what you do!
Thanks for your sacrifice in the heat Justin. Great video with awesome arc shots as usual.
Great job with excellent tutorial, thank you sir!
Absolutely amazing arc shots. Well done. Your skills still amazes me. Carry on my friend.
I've never done tig but always want to learn it. This is excellent. Really enjoyed it. Loved the 4G63 collaboration with Mankandy too. From Australia 🇦🇺 where it gets just as hot, thank you Jason.
Excellent video and instruction!
Excellent work and great video. Thanks
Thanks for the video, I picked up a lot of info especially watching your technic.
You are always worth a watch and a like!
good video. it really shows the crap you get with aluminium repairs. aluminium soaks up crap and looks exactly like that when welding.
maybe for the next video is show doing it with a stainless backer.
wish i had you're foot control man, awesome video, you explain it so well.
thanks for passing knowledge on.
👍👍
😁 I really thought you were going to say 88 instead of 90 and make a back to the future joke. Super work, making me want to take up welding 👍👍
As always, exceptional!
Very good and it looks like fun.
You should Get a little Glass Dropper Bottle for Your Vinegar Test. Would take up less space on the tool cart, you won't need to worry about over pouring Anymore. Plus it will Appear more "Professional"
You ended up capturing arc shots that look clearer than when I'm in a hood. That's wild!
Outstanding Justin...always good, cheers from Orlando FL
It's nice to see welding, and fabrication being a good career path in USA. I am from India, and I have been in love with welding since when I was 15 or so. Couldn't make a career out of it, so became and engineer only to learn that the money lies outside the shop.
You make is look so easy. Nice job
nice vid. i don't watch all of them, but when i do have the time to, i always learn something.
A 20+ minute video... Yes Please!! 👍👍
I'm liking the low production vids. The real value in your vids was always the knowledge drop anyway.
this new camera setup is incredible
Great video
Good Effort !!
Learnt a lot from this. Thanks!
I feel like I’m getting better just watching you !
Your back hell yeah thank God missed ya 😁
Superb man!
Love the videos and education
Thanks Justin
Used to love ally tig welding never done cast aluminium
I fill holes that our machinest from time to time on adelet boxes, there basically large eletrical boxes for breakers and such ... them suckers are some times 2" thick maby more. I basically beval both sides and weld from the center out... there a really good aluminum casting
Great video! We’ve seen so many vids on cast aluminum weld repair, but what about welding pieces of cast aluminum together? For example, I’ve got a turbocharger compressor housing onto which I need to weld a 90 degree elbow. Would love some tips on how to make that happen.
I have an engine that the rod got shot out the top on and can’t get a new engine for it so I was thinking I might weld the case back up and just rebuild it myself so this popped up just in time as I was pondering the possibility of it and the vinegar test is really helpful I’m no master welder I’m running a Vulcan from harbor freight and it’s an old Kawasaki mule side by side engine so I’m not expecting art work just sturdy lol
Very well done. Putting the heat to it and letting the crap (internal porosity in the casting) bubble out like you did is essential to getting a sound weld. It takes patience, but is the only way to do it.
And Sometimes you get so much crap, that you have to Wire brush it off quite a bit, but it is worth it in the end.
Thanks!
Welding cast aluminum is just a gamble it feels like, because you dont know what you have on your hands really. Sometimes it just seems to blow itself apart, sometimes its so uneven you go from an easy weld into molten aluminum spraying everywhere. Most of the time there is just a lot of bubbles and you have to work a lot to get them all out.
Most people just see a tiny hole that needs to be filled in (if we are talking about this piece here) but for us who has worked with cast aluminum before, what we see is a minefield. Sometimes it looks like an easy job, you almost want to tell the customer, give me 20 minutes and it will be fixed, but as soon as you start working on it, you feel like it would be a lot easier to just remake the whole part.
thanks for the pricing ,, these are the jobs I find hardest of all to price .
A few decades ago the owner of the company I was working at saw it as a personal mission to find something that I couldn't weld. One day I came in and found cracked Mickey Thompson magnesium wheels and Vick Edelbrock manifolds from their first years. A taped up and purged sandblast cabinet got me through the mags.
Thanks
Lennox Lube Tube wax for all things aluminum including burrs, 4-1/2" carbide saw blades, carbide chop saw blades, band saw, etc...Plus, you can weld thru it.
I always used the pipeliner backing pads for my gloves they just slip on with a couple elastic straps, and you can twist them around to cover where ever you need them. Would be nice if you included the settings for the video (miller Dynasty 90A 85Hz - 4563 rod 3/32 and 1/16) sort of thing.
Perfect video, I literally have to weld cast aluminum today on a boat engine cover….should be fun….I hope….
I dont know if i missed it, but what alloy filler do you use on cast repair? I hear different things and was just wondering if there was one you preferred over the other. Great video with some excellent arc shots! As usual 😉
Seems OK ;-)
Nice work!
Stick your cutter into wax - see the difference it doesn't clog up as much.
Used to do that for a living.
I dig the white vinegar test.
Something to try, if you want to reduce clogging on those rotary files, is to briefly run the file in candle wax before you start, it doesn’t stop it, but it does reduce it enough to make it easier to clean off with a file card, then just rinse-repeat.
what machine do you use for most of the welding you do? i was thinking about buying a everlast mts275 for my first welding machine but i really wanna learn mig and tig to be able to do both and watching your tig welding just makes me wanna learn so much more because you make it look so easy even though i’m aware it take a lot of practice and skill to get there. i’m aware it’s a lot for a machine but i’d wanna be able to do multiple things with it. not just one type since i’m not always gonna wanna use one type of welding depending on the things i’m doing. i just wanted to know what a skilled welder like yourself runs most often
Hey Jason great video as always and thanks for the tip on Aluminum vs. Magnesium identification. That's so simple and I've always wondered how to tell the difference. I also see you tossing the last little bits of your filler rods, how come you don't join them and continue?
Again, great stuff. Been following you on and off since your garage and always come back.
Keep it up man.
Mark.
Yes, Being able to tell the Difference between Aluminium and Magnesium would be helpful so that is a simple clever trick, thanks. With the Filler rod ends, I've got Scottish lineage, so being "penny pinching" is in my blood, I always weld my new rod to the Last stub, and Continue, it only takes a second.
Excellent video & information! Using LaYZr tungsten....? 😁 Thanks!
Impressive how little shaking there was if you had your arm floating holding the torch that far up. Well played.
it looks easy to you. what size diameter of tungsten do you use? and what gas pressure do you use?
Like all your videos and the time that goes into them. Love the knowledge you provide for free. This video had me feeling sick early on and I had to put my phone down and just listen. Those with ADHD and autism may enjoy it more than I did.
Nice job and nice gloves 😂😂😂
*I want to see a competition between you and whats his name from fireball tools in a tig welding showdown. NO GLOVES AT ALL. The one who welds the most without stopping wins. And must weld in an enclosed box like this manifold you're welding. I would totally pay to see that.*
I second that.
I third that.
I’m never welding anything without gloves so there.
@@fishhuntadventure Yeah but we weren't asking you.
@@fishhuntadventure You maybe but think about it. Someone who would do this could get rich off the pay per view because you know people would watch it.
Excellent video and love your channel. Quick question. I’m a beginner and have a stick mug and flux core machine. I am using those for simple repairs around my hobby farm. I do not have a TIG machine nor do I know how to TIG weld. How would I go about doing a cast aluminum repair with a mig machine? I have a spool gun for it.
A backer or purge would help with that porosity. A purged cabinet is the easiest way to deal with a lot of things.
As little Ring Around the Rosey I like to call it.
am i the only closing my eyes when he says "listen to the arc"?
$200 for that quality of work, when can I hire you?! Lol
I know you did a video on welders but for some reason I can't seem to find it. Must be sleep deprivation from the new baby! But what is you recommendation for a ac/DC tig machine around the 1k mark. Not going to be used in production, just whatever fun projects I have.
Do you run an ND filter for your arc shots? I got some ND filters to try the same, but I'm not sure anyone who does welding videos ever talks about how they set up arc shots.
What tungsten is that ??? That staying pretty sharp for AC .
Please do a video on how to connect a tig torch to a welder. Also on the different connectors ,how those work and how you know what size they are, and how you know if it is a twist mate, 1/2 inch terminals, tweco style. I have a Lincoln weld pak 180i mp dv and want to get a K1782-17 (PTA 17) 1 piece torch for it but I’m not sure if I have to order an adapter to hook it up to my machine or which one I would need I’m just confused man and need help!
I would just like to caution that some die cast parts are made with a Zinc base alloy. Interesting thing is that the density of Aluminum is 2.7 grams/cm^3 and Zinc is 7.13 g/cm^3. The interesting thing is that the density of Zinc is only slightly less than that of Iron which is about 7.2 grams/cm^3. So if you pick up a die casting that is quite heavy for the size chances are it is a Zinc based alloy. Just for information the density of Magnesium is 1.74 grams/cm^3. Zinc does have a higher strength than Aluminum or Magnesium so that is why it is sometimes used in die castings.
PS: What is the part used for? Just curious.
PPS: Very Nice demonstration of technique on the filling.
Which prime weld were you using
I love hearing a SAILOR say that they get motion sick...! 😂😂😂
Assuming you are using an iPhone or a gopro, it would make the handheld shots much less vertigo inducing, if you would use the image stabilizing feature.
I LOVE the information you put into your videos and your presentation skills are
excellent, and missing parts because i have to look away from the bouncing screen is disappointing.
What filler rod did you use?
Question, I recently tried a dirty aluminum cast, and while going over with the ‘cleaning run’ everything that bubbled up and ‘cleaned’ as you will - that just separated from the main casting and almost fell off. It just becomes a blob of clean aluminum thats not adhered.
Do I need to preheat more? Or is this just something that could happen with old aluminum cast
I did do physical cleaning before as much as I was able to.
What level of ND Filter do you use on your camera for these welding shots?
Almost reminded me of brazing.
Is it possible to wire feed fill vacuum ports on an intake manifold?
Can you tell me what you welding table is called and where you bought it? Thanks
You need a bigger swamp.
Who or where do you buy your carbide bits at? I keep buying Chinese ones to “save” money and it’s just standard steel. Shit gets eatin up on anything I use it on but plastic.
What welder are you using
I’d love a foot pedal on my welder. I do similar jobs regularly, and I’ve got to keep adjusting the power dial and pulsing the trigger on and off to keep the heat where I want it.
Gm aluminum valve covers have alloy metals elements protruded/casted from inside. too bad they didn't include percentages though it would be cooler
hey Jason, just wondering what filler you prefer to use on castings. 6061 4043 or 4047.
I have been told that the 40 series has more silicon and stands up to heat cycling better.
Appreciate your videos thank you.
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