Welding save of a cracked 064 case

[srcarr52]

This 064 case half had a bad day with a case splitter which ended up cracking the cylinder mounting flange. Luckily it was only cracked in the vertical and the piece could be bent back limiting the amount of the gasket surface that needed to be welded.

 

[srcarr52]

With some heat and a clamp I carefully bent the section back into place and ditch cut the areas to be welded.

 

[srcarr52]

Then a little tig action using az61a mag filler and the lightest amperage I could get the puddle to flow.

 

[srcarr52]

The final result after finishing back the welds and carefully trueing the deck surface by hand with a file and a flat plate and some 400g sandpaper. The case gasket surface was trued with 400g on a granite block.

 

[BuffaloBill]

Nice job on the repair! I’ve never welded magnesium. Does it TIG similar to aluminum?

 

[Junk Meister]

The final result after finishing back the welds and carefully trueing the deck surface by hand with a file and a flat plate and some 400g sandpaper. The case gasket surface was trued with 400g on a granite block.

View attachment 408482 View attachment 408484 View attachment 408485

Impressive.

 

[srcarr52]

Nice job on the repair! I’ve never welded magnesium. Does it TIG similar to aluminum?

Pretty similar, you'll want more gas coverage as it oxidizes easy like stainless.

 

[David Young]

Thanks Shaun,
this is one of the things I would like to try. this is a good pointer to get me started. you always make your repairs look factory when you are done.

Nice work!

 

[drf256]

The final result after finishing back the welds and carefully trueing the deck surface by hand with a file and a flat plate and some 400g sandpaper. The case gasket surface was trued with 400g on a granite block.

View attachment 408482 View attachment 408484 View attachment 408485

Nice work, as usual. May I ask why you didn’t use AZ92 filler? Did you switch it up?

 

[srcarr52]

Nice work, as usual. May I ask why you didn’t use AZ92 filler? Did you switch it up?

I've used both and I haven't noticed any differences. AZ61A was all they had in stock the last time I ordered.

 

[Steelie90]

Great work!
What tungsten did you use? Argon or helium?
I did my first repair with az92, definitely a learning curve. I kept getting lots of porosity.

 

[srcarr52]

Great work!
What tungsten did you use? Argon or helium?
I did my first repair with az92, definitely a learning curve. I kept getting lots of porosity.

2% ceriated, argon 35 cfh with a #10 gas lens.

 

[buckin-wood]

you've inspired me to dust off the syncrowave. I assume I'm cranking the balance to 9? turning the little amp knob to 200.. mashing the pedal and magically beautiful stacks of dimes will appear ?

 

[srcarr52]

you've inspired me to dust off the syncrowave. I assume I'm cranking the balance to 9? turning the little amp knob to 200.. mashing the pedal and magically beautiful stacks of dimes will appear ?

Probably not. Mag doesn't seem to like a whole lot of cleaning action and it will burn off if you step on the go pedal too much.

 

[buckin-wood]

no stacks of dimes were had. fooling around a bit on a junk case to see what I could do about fixing the mating surface...





had the machine at 85A, but didn't need all of that to get a bead going on the edge. 2% ceriated, straight argon, AZ61A, left the balance at 9. I'll play with the settings some, but seemed to go ok for the first time with mag






thanks for the moment of inspiration. your post reminded me that I had picked up a tube of mag filler rod a few years ago to fix some dolmar cases that have been on the shelf even longer.

 

[srcarr52]

no stacks of dimes were had. fooling around a bit on a junk case to see what I could do about fixing the mating surface...


View attachment 408777


had the machine at 85A, but didn't need all of that to get a bead going on the edge. 2% ceriated, straight argon, AZ61A, left the balance at 9. I'll play with the settings some, but seemed to go ok for the first time with mag

View attachment 408778

View attachment 408790


thanks for the moment of inspiration. your post reminded me that I had picked up a tube of mag filler rod a few years ago to fix some dolmar cases that have been on the shelf even longer.

Looks good. Usually with mag rot you need to grind out all the dark spots or they'll flare up and put carbon all over the weld area. Fixing mag rot can be a never ending mess.

 

[Steelie90]

2% ceriated, argon 35 cfh with a #10 gas lens.

I’ll have to pick up some ceriated and bump my gas next time. Hopefully it holds

 

[srcarr52]

I’ll have to pick up some ceriated and bump my gas next time. Hopefully it holds

Ceriated isn't necessary. My welder seemed to like it a little better for low amp arc starts, that's all.

You should build the spike side back up. That area is supposed to be flat but it has been worn into by the spike.

 

[Steelie90]

Ceriated isn't necessary. My welder seemed to like it a little better for low amp arc starts, that's all.

You should build the spike side back up. That area is supposed to be flat but it has been worn into by the spike.

I thought they had a “pocket” for the dog in the cast. I’ll have to look tonight.

 

[drf256]

2% ceriated, argon 35 cfh with a #10 gas lens.

That’s a shít-ton of Ar. I’m much cheaper and go 10 on Al and 8 on steel with a #8 lens. You really feel that 35 is necessary for Mg?

I usually use 65-75% EN on Aluminum, depending on how clean it is and how many amps I need. What settings do you like for Mg?

Have you ever played around with pulse on Mg?

I also use 2% lanthanated for everything except when going side-ball (the pure W trick you taught me).