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Cast Aluminum Ford Ranger Intake Manifold Repair

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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Intake Manifold

This Ford Ranger 2.9 L intake manifold had a broken EGR valve mount. 



Intake closeup1 
As you can see, on the left hand side--bottom and top--it is broken through the threads on both sides. 



Closeup 2 
We beveled the top to ensure good penetration into the crack. 



Closeup 3 
Using Super Alloy 5 and an oxyacetylene torch, we made the repair in under 5 minutes. 



closeup 4 

After the part cooled, we sanded the welded area smooth and reinstalled in the car. 



Thick aluminum requires oxyacetylene, oxypropane, oxynatural gas, or oxyMAPP gas to heat the base metal to the required 600 degrees. If your flux is not liquifying, it is because your base metal is not hot enough. To increase bonding strength, always add flux every time you add rod. Always keep your flux bottle as close as possible to the repair area, because every time you move your torch away, the aluminum drops approximately 100 degrees per second.

 

Super Alloy 5 Products

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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 ..

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

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

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

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

Super Alloy 5 Replacement Flux
Super Alloy 5 Replacement Flux

1 container powder flux (shelf life 1 year) ..