Opinions on welding cast and these being salvageable

[TerminalTalon]

Helen Keller decided to try welding years ago and now I need some opinions. What do you all think about real repairs to both the block and the tcase?

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[FIBA M - EC17PSE]

Cast alloy is ok but its a bugger as it contains alot of silicone and is problematic. It requires it to be very clean and pre heated and again very super clean as possible!

Cast blocks are not something i specialize in, i have welded some iron and steel blocks but they were special rods for the iron blocks. Steel blocks of today might be more weldable but would likely suit tig welding and again clean oil free and pre heating helps alot! On this i would perhaps google the block welding and see if weldingtips and tricks says about it. They might even have a video on it also for you.

 

[bastarddsm]

I've welded a few DSM blocks over the years. I used nickle99. Weld a short bit, stop, peen with air hammer, weld more. Keep it cool. I've seen guys mig weld them and it seems to work. I've also seen them brazed. For the most part though it's a temp fix and a death sentence to block.

As for bellhousing, I fix them all the time. But it comes apart and gets run in a cuda parts washer FOREVER that really sucks the oil out of the pores. The crack gets veed out and welded up. Most just try to lay a caterpillar on top of the dirty crack and hope for the best.

I have one to fix right now that's got a pretty good size hole in it where some shrapnel went through. The actually weld pretty good when you get them clean. Often they want to blow some porosity right next to the weld. Die casting alloys are often like that.

 

[TerminalTalon]

I’ve already had one welder say it looks like it’s too far gone but I’m hopeful. It looks like Helen Keller played welder with an Amazon welder.

 

[TerminalTalon]

I've welded a few DSM blocks over the years. I used nickle99. Weld a short bit, stop, peen with air hammer, weld more. Keep it cool. I've seen guys mig weld them and it seems to work. I've also seen them brazed. For the most part though it's a temp fix and a death sentence to block.

As for bellhousing, I fix them all the time. But it comes apart and gets run in a cuda parts washer FOREVER that really sucks the oil out of the pores. The crack gets veed out and welded up. Most just try to lay a caterpillar on top of the dirty crack and hope for the best.

I have one to fix right now that's got a pretty good size hole in it where some shrapnel went through. The actually weld pretty good when you get them clean. Often they want to blow some porosity right next to the weld. Die casting alloys are often like that.

I might take you up on that for the trans case repair and a rebuild.