How To Weld Aluminum Valve Cover

I welded a piece of aluminum under the breather hole on my last valve covers but it left a small mark on the outside. While I was welding the valve cover I was reminded of some basics for welding aluminum.

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Rough saw cuts should be smoothed with a file carbide burr or other method that wont introduce any foreign matter on the.

How to weld aluminum valve cover. The aluminum particles contained in the epoxy will adhere to the cracked part creating a permanent bond that will hold up in most situations. Sure all welders want the stack of dimes look but its not always possi. 07-02-2016 1221 PM.

Valve cover manufacturers offer load spreaders that go between the bolt and the cover and spread the bolts load go figure over a wider span but the best fix is to just not get so aggressive with the ratchet and socket. The client emphasized that the weld had to be blended in without creating a dip in the area. Let it dry overnight somewhere warm to ensure the crack is dry.

Use a tip size 2 larger then then for steel set a hot flame to tack slightly reducing. Working thru this valve cover project I was reminded of a few tips for tig welding aluminum. Tig weld the crack in multiple small passes with carefull grinding between each pass.

Wipe all tape residue glue oil grease paint etc with a solvent like acetone before starting. Wipe all tape residue glue oil grease paint etc with acetone. I thought I had blended it in well with minimal material.

Use a dedicated aluminum only wheel to groove the crack and use a dedicated stainless steel brush to clean the grooved out area. Gas flow should be regulated between 16 and 18 cubic feet per hour for aluminum. I repaired it in the usual manner drilled the ends gouged out the crack pre and post heated it after welding and let it cool slowly.

One note of caution though. That one I just put on finger tight. For those times when solid strong welds are needed over aesthetically looking beads.

For welds needing deeper penetration an argonhelium mix is recommended. I would allow a technical alcohol pooled in the valve cover to leak through the crack from the inside to the outside until the outside wipes clean and dries fast. Some most of the AN fittings are anodized.

Both locations are relatively close to each other on the valve cover. IE there is no more oil. I was wondering if jb welding a piece of aluminum under the valve cover would work.

Hi all I did a job today repairing a six inch crack on a hard to find aluminum valve cover. Warm the parts and filler a bit brush on the flux so it dries on. I have not seen anyone weld that part before but people weld fittings for catch cans all the time.

In a nutshell. Cracked aluminum can be adequately repaired without welding using an epoxy embedded with aluminum. EOD is right about one thing though you will probably want someone who can do.

This will eventually get you clean solid base metal that will form a. Eventually the bolts are tightened to the point that the valve cover flange distorts and creates a leak at the gasket. You can try to stop-drill the crack but then that is more area you hope to seal.

You have no items in your shopping cart. Or chuck them in the lathe and take a skim cut in the area to be welded Last edited by H80N. The valve covers are not aluminum bro flip em over and you will see the markings underneath that say it is actually a magnesium alloy.

3 Aug 6 2013. The proper way would be to weld the fittings above the baffle like this. If theres nothing there to keep them separated then one will pull on the other and the crankcase will not evacuate properlyefficiently.

Better just JB Weld the crack now at its most open position then while the JB Weld is still liquid back off the torque on the adjacent bolt and evenly on all the other 10 bolts as well. Provided you have the right flux mix some with bottled drinking water to form a thick paste. Clean the aluminum with alcohol and the stainless brush.

To ensure proper adhesion you need to prepare the surface of the cracked. And need to have the oxide scrubbed off before you try to weld. Any tape residue or oil will muck things up quickly.

THese valve covers are two nice and exspensive to take a chance on. I then applied a fresh bead of Permatex The Right Stuff to the top and bottom of a fresh valve cover gasket and tightened the nuts on all the studs except the one screwed into the cracked boss.

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