Diecast aluminum

[Stevdar]

Hey does anyone have any ideas on welding Japanese motorcycle cases etc. I can weld them ok with a tig but it's very hard and takes ages there must an easy way or is this stuff just crap metal and is difficult to weld.:confused:

[Pangea]

There is no easy way on cast aluminum. Clean it, run an autogenous pass to burn the crud out. Grind and clean again, then try a pass with wire. Once you build a base with new filler wire it gets better and better because you are welding over less and less cast.

[yorkiepap]

Hey Stevdar,
Pangea gave you sound advice concerning aluminum. I will add that you must be mindful that aluminum is the most finicky of metals to weld because it has to be immaculate as far as cleanliness..... virtually "germ-free". Those japanese motorcycle cases are excellent quality aluminum castings & will weld quite nicely....IF.....you can get them clean. Oil will impregnate in the casting & is very detrimental to a good weld. I strongly suggest to get some acetone & soak overnight in an air-tight container to eliminate evaporation. That will start to dilute the oil. Then a vigorous brushing with a SS brush & acetone again. Warming the case with a propane torch will also "lift" some of the oil to the surface to again be brushed with acetone. This may take several applications to get it somewhat receptive to welding. Do not use a brake cleaner, laquer thinner, or any other solvent except maybe denatured alcohol. D/alchohol does not have the strength as acetone. Acetone works best. BE SURE NOT TO HAVE AN OPEN FLAME OR SPARK ANYWHERE NEAR ACETONE!!!!

You will get better results with 4043. Just bear in memory that it HAS to be clean.

Denny

[mikecwik]

in my readings a lot of people bake the parts to help with oil removal.

[SidecarFlip]

in my readings a lot of people bake the parts to help with oil removal.

Somehow, I can't see my wife tolerating that scenario.

[usmcpop]

Somehow, I can't see my wife tolerating that scenario.

She hasn't heard about Hayabusa Bundt cake? :confused:

[SidecarFlip]

She hasn't heard about Hayabusa Bundt cake? :confused:

Lordy....

She already has to tolerate numerous motorcycle rally's and trade shows where I pander my goods plus a garage full of late model and vintage British bikes and she don't even like to ride, let alone think about me 'borrowing' her oven for some project. Between the bikes, the business and my gun and reloading fascination, I'm suprised she hasn't gone wacko.

On the flip side, I tolerate 40 or so cats, 5 dogs. 4 horses and her snoring.:D

I don't snore. At least I've never heard myself snore.:eek:

[vwguy3]

"Clean it, run an autogenous pass to burn the crud out. Grind and clean again, then try a pass with wire. Once you build a base with new filler wire it gets better and better because you are welding over less and less cast."

This is good advise.I attempted to repair a small engine carb just to see if I could.It look lots of cleaning,grinding,adding of filler to get a decent weld but I was sucessful.