Ernie, help :)
I have a friend who wants me to weld up some holes on a Honda cast AL intake manifold. I haven't seen it yet, but I know welding on cast AL is tricky.
I need advice on the best filler to use and the process. I believe I'll need to clean it well, bake it in an oven for some time to get oil out of the pores, preheat it with O/A before welding and then TIG it. Possibly clamp a piece of copper to the back side of the hole to provide support while filling.
I've got O/A for the pre-heat, a Syncrowave 250 for the TIGing and an IR thermometer to check the pre-heat.
Thanks,
Pete C.