I had to build up with weld the inside of a 1.125 bore because it was off location about 1/8" in two directions. So I needed to put metal in
1/2 the hole so I could rebore the hole on the proper location. The hole is about 4 inches long and goes clean through the part so I could weld from both sides. I tried TIG but just couldn't weld very deep. Couldn't get the torch is far enough. I do have a little Lincoln SP125+ welder but the part is aluminum and the little welder isn't really man enough to weld thick aluminum. So I tried pre-heating the casting up to about 400 degrees and I was able to get sound welds. But I still had problems getting deep into the hole. So I took the contact tip off the torch, put it in the vise, and bent it with a hammer and an aluminum punch. Then I ran some titanium welding wire coated with Timesaver lapping compound and oil through the contact tip back and forth to smooth out the inside where it had collapsed a bit from the bending operation. Now the wire comes out of the contact tip and curls down so I was able to weld very deep into the hole. I know, a little welder, pushing aluminum wire (barely), through a bent contact tip, is really pushing the envelope. But I got 'er done dammit! Now I get to have a beer while the casting cools. Tomorrow I rebore. Later, Eric- posted
9 years ago