> 2024-T3 for the base and .063" 2024-0 for the sides and top. I'm a beginner
> so I don't know if it makes a difference that the base is heat treated and
> the sheet is not. What wire and gas should I use? I think I need ER5356 and
> he-75, but I want to make sure. This is actually my first welding project. I
> have a small 110v mig machine.
thereabouts. Never seen one welded, but shrinkage could be a problem when
you try to get it seated on the engine block.
If you had a casting, you could easily machine it nice and flat to get a
good mating surface. Might look real nice in bronze all polished up.
If you cast it - you can make any design you want, art deco, hot chick,
logo, lettering, whatever.
You could probably come up with a VERY slick looking valve cover by welding
pieces together to appear like a heat exchanger, but I'd keep the base a
little thicker so that you can polish it flat in case you get any warpage.