I'm beginning to think there are no easy cheap ways to do repairs on
aluminum. I've tried two different torch weld alloys and gotten mixed
results at best. The biggest problem I've found with those though is the
expansion and contraction of hte metal. I can do very small repairs, but
for anything bigger it breaks itself, or melts the weld further back as you
try to work along further up.
You just have to invest in the right equipment I guess.
$100 to weld, $130 to replace the entire pump. Thanks, guys - not the
answer I wanted, but it sounds like a solid consensus.
I'd double check that price with another shop. I don't know where you are
located, but that sounds a bit like rape. Did you pull up in a limo to have
it priced, or is the job a lot more complex than it sounds.
I had a call from a guy on the East Coast who was desperately trying to
find somebody willing to weld a really expensive timing chain cover for
a BMW sports car.
I explained that I was willing to weld it, if he could ship it to
He then explained that he thought it could be welded ON THE CAR!!!.
I had to explain to him that that is impossible.
The part would have to be removed, cleaned, and degreased completely.
Then preheated, welded and then slow cooled.
He thought the shops he had taken it to were trying to rip him off.
After my explanation he understood why their estimates were so high.
Aluminum can be welded, but it takes equipment, knowledge and training
to do it right.
Welding ally is in the realms of a black art , however all is not quite
lost there is an aluminium soldering rod which I have heard good reports
on for repairing automotive waterpumps and similar castings( land rover
group). I bought a pack but so far I have been lucky and not needed it.
This is a link to a UK supplier on ebay you should be able to find
somebody closer to home
I've used this and it can be useful. It's main limitation is the low
tensile strength of the joint. Filling-in is good, structural
not-so-good. In the OP's case, if the length of the tube beyond the
break is significant, or there is any significant mass at the end of the
tube (e.g., a filter), then vibration could put too much stress on the
joint. Hard to say without pix. Also, not something that you want to
Yikes - $75/lb! I bought mine for about $17/lb in the hardware store.
That brings up another good point. Aluminum is a lot more sensitive to
welding without post welding heat treatment the steel alloys. If this tube
is indeed a structural element in an area of high vibration, even TIG
welding it without restoring the heat treatment could be a lost cause.
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