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Repairing an Aluminum 1959 Porsche Bumper Guard

Testimonials

Mike,

These pics come from a new aerospace test facility that they are constructing at the University of Notre Dame. The SSF-6 is working great.

 

aluminum welding and metal repair

I am attempting to make all of these fittings air tight as they are used for pressure measurements. We can¹t have any leaks. I had very little warpage of my base metal and I think this is really going to work out very well.

 

metal fabrication and repair with muggyweld

Thank you,

 

David Hipskind
Turbomachinery Technician
The University of Notre Dame
Institute for Flow Physics and Control (FLOWPAC)
The Hessert Laboratory for Aerospace Research

 

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Received 9/24/2010:

Which Muggy Weld aluminum rod is appropriate when restoring a 1959 Porsche bumper guard? Because Super Alloy 5 brazes and is great for large projects, while Super Alloy 1 is a multi metal solder that is used as a finishing rod and for small imperfections, both are excellent choices. Longtime Muggy Weld customer Bob Chase provided a photo series illustrating his restoration of 1959 aluminum Porsche Speedster bumper guards using both Super Alloy 1 and Super Alloy 5. He was able to save the original aluminum parts and restore the bumper guards to a flawless condition.

 

This 1959 Porsche bumper guard was missing a large portion at the end of the part. Super Alloy 5 was laid across the hole to bridge the gap.  One of the unique characteristics of Super Alloy 5 is that you can use it to build up, out or across.

 

 

This is another view of Bob's work. Bob was able to bridge the gap and give himself room to grind by building the Super Alloy 5 on top. Oxy-acetylene was required for this restoration because of the mass of aluminum. Aluminum dissipates quickly so oxygen is needed with your gas of choice.

 

 

The bumper guard on the left also had a few small imperfections. Bob chose to repair them using Super Alloy 1 multi-metal solder. Almost any torch can be used when working with Super Alloy 1. If oxy-acetylene is used, turn the oxygen down since Super Alloy 1 melts at a very low temperature.

 

 

Super Alloy 1 restores aluminum as shown, but also works well on most white metals including pot metal, zinc die cast as well as copper, brass, bronze and steel. Many of our customers purchase Super Alloy 1 for a specific alloy or metal but because of it s versatility keep it on hand for future projects.

 

 

Bob sanded and shaped the aluminum. Aluminum is soft and doesn't need heavy grinding.

 

 

The Porsche bumper guard has been polished and is ready for the last step, in this case chrome plating. Since Super Alloy 5 is a perfect color match, you can paint, powder coat, chrome plate or polish the aluminum. Our thanks to Bob Chase for sending in his photo series.

 

Notes from Bob:


Mike,


Here are some before, during and after pictures of a 50 year old 356 guard that was broken in four pieces. I did use some allow 1 on this for small imperfections, but the rough stuff was done using the alloy 5. Final picture of 1959 high bar built by yours truly and the rebuilt guard after chroming. Regards, Bob

 

Bob Chase
Grey Eagle Overriders

 

Super Alloy 1 and Super Alloy 5 Solder Products

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Super Alloy 1 Starter Kit 3/32"
Super Alloy 1 Starter Kit 3/32"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die cast..

Super Alloy 1 Starter Kit 1/8"
Super Alloy 1 Starter Kit 1/8"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die cast..

Super Alloy 1 Full Kit 3/32"
Super Alloy 1 Full Kit 3/32"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die ..

Super Alloy 1 Full Kit 1/8"
Super Alloy 1 Full Kit 1/8"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die cast..

Super Alloy 1 Replacement Flux
Super Alloy 1 Replacement Flux

1 Jar of Honey Liquid Flux (shelf life 2 years) ..

Super Alloy 5 Starter Kit 1/16"
Super Alloy 5 Starter Kit 1/16"

Super Alloy 5 is the 600°F aluminum brazing alloy--bonds at half the melting point of aluminum ..

Super Alloy 5 Starter Kit 3/32"
Super Alloy 5 Starter Kit 3/32"

Super Alloy 5 is the 600°F aluminum brazing alloy - bonds at half the melting point of aluminum ..