Mark, Any thoughts on leak testing the welds? BTW I really have enjoyed reading this thread. Great vision. John
The ifrst pic shows how deep I cut the one side on the first head....about 2mm too much. The second pic shows how perfect head 2 is, it just needs a tough of blending and it will be perfect. So, I started filling in the over-cut on head 1. 2 ports done before little one got bored, 3 to go (this is the head with the test port, so only 5 to work on). Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
I have thought about it but haven't come up with any easy way. I'm thinking I may go with the ignorance is bliss method. I remember soem years ago I was builting something...an intake manifod maybe and a buddy asked about leak testing and my answer was "I welded it, why would I leak test it?"
Uhhhh.... We are all going to run with the concept that your welding is better than your spelling... <ducking, running for cover> Rick
I made the mistake of showing my wife my finger tips under a microscope once and she could see all the very tiny metal chips embedded in my skin. Our relationship hasn't been quite the same since.
Leak testing heads is a good idea. If you don't have the set-up for it, a local engine machine shop should be able to do it for you fairly cheaply.
I would hope so. I had a teacher once asked me if I was getting zeros on her spelling tests on purpose......sadly a zero was simply the best I could do.
Ha... I had one ask me the same thing about multiplication tables!!! <memories> I'm willing to bet your teacher couldn't make the things you do!!! If you don't own your tank - when your current bottle of Argon goes flat, you really should try the Argon/Helium mix. I was amazed at the difference it made too! Rick
I do own the tank and I do weld steel so Argon is required. I'll ask about a second tank when I get a chance to run over to the welding shop. Now you guys could have suggested this 2 years ago when I had a lot of Aluminum to weld
Mark: I just came across this thread. Late to the party, but better late than never. It is amazing what you are doing! By far the most impressive thread on FChat IMHO. For sure I'll be following this every time I log on from now on. I have some questions on the aluminum head welding. What sort of TIG welder is necessary for this job (AC or DC). What sort of voltage and amperage setting on the welder? What type of welder tip? And what aluminum rod to use? How do you prepare the head to clean off the oxides? And what temperature do you preheat the head to? Sorry if my questions seem rudimentary, but the only time I touched a TIG welder was 25 years ago in college. I have a couple of 360 heads that have serious corrosion around the combustion chamber gasket sealing area too deep to be simply milled out. I'm now inspired by your thread to attempt a repair on them with welds to build up the corroded area. Regards, Wayne
Rick: Can you elaborate on the benefits of argon/helium mix in this application? I am a curious welder wannabe. Thanks
Wayne, You need AC, at least a 300A machine with a water cooled touch. Preheat to about 250-300 and use 4043 fill rod. wire brush for clean up/ prep. No matter how hard you try you will get .005" or so of burn in line around the weld so plan on needing to deck the heads at least the .005". good luck!
I don't want to high-jack Mark's thread, but Helium (can be used up to 80% mix - I like 50/50) adds energy to the weld. I was told by the guys at Barnes that with Helium in the shield the arc carries more voltage to weld site without any increase in current. When using straight Argon - after you strike, it takes a bit before you see the puddle. With a good Helium mix it seems to puddle almost immediately and the welds look cleaner. I'm a hack welder compared to Mark, but with Helium in the mix I do pretty good... especially on thick stuff. Rick
No more holes in heads 1 it's welded, rough ground, and ready to have the bottom put in. Head 2 needs a lot less work so it should go a lot quicker than this one did. Image Unavailable, Please Login Image Unavailable, Please Login
Ok, no more holes in the heads but it came at a price.....the mini-torch Wil lent me burned up tonight so the port work will stop while I wait for a new torch (well 2 new torches, one for me and one for Wil) to get here. It turns out there is a limit to how long you can run a 125A torch at 200A. This is where a little helium in the mix might help are it allows better energy transfer and lower amps settings. Edit .that is an expensive torch I burned up that uses really expensive collets and gas cups. I see they also have a 180A torch that is about ½ between the mini and what I currently have that should still fit in the ports for at least most of the work ..Im thinking Ill order the semi-mini torch for me and a replacement head for Wils torch and that will keep the bill under $800 ..
Ouch Mark! I haven't bought one of those mini torches. The WP-18 and WP-20 were enough for me, thanks. Although I will need one at some time. I can't believe you are welding a cylinder head at that low an amperage. I crank my machine up to 320 to weld my heads. And yes, the helium mix does help. In fact I have a bottle of straight helium I will try. I have heard that straight helium is great for aluminum. I'll let you know. Tom...
You need to grind the ports until they are paper thin, they weld a lot easier that way a 20 is what I usually use, but I do have an 18. I'm going to order a 24 and see how it works out for stuff like this....it's 1/2 the price of the WP-125 Wil lent me and the collets and cup are a LOT cheaper, like 1/10th the price.
I looked it over, it just needs a new front rubber sleeve and inner body so it will be the same torch coming back good as new. I hadn't looked it up before and was just a little shock at how many $ of damage I'd done....really handy torch though.
I got the torch stuff ordered up today and while I was at it ordered the Suzuki springs to have a look at. I'll start fitting the port bottoms now I guess and weld what I can with the big torch.
