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Brazing Cast Aluminum: 1996 Honda Motor Mount 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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This cast aluminum 2.2 liter engine block came off a 1996 Honda Accord that had been involved in a minor traffic accident. The front motor mount stud was broken off, and cost the customer around $1900 to replace. ($1000 for the motor, $900 for the labor)

 

Steve at Alternative Automotive in Sarasota, FL was hoping we could save this rather than scrapping it, so we grabbed our Super Alloy 5 and an oxy-acetylene torch and went to work.

 

 

A close up of the broken stud.

 

 

Watch for the cast aluminum to look slightly porous, indicating that the rod will flow into the metal. Always use a dark pair of glasses for eye protection, as well as to enable you to see through the bright flame.

 

 

Super Alloy 5's flux allows us to make the repair without cleaning off the oxidation. We pre-heated the entire area for 2 or 3 minutes before starting the repair, to get the aluminum up to temperature.

 

 

We used an oxy-acetylene torch to allow us to keep the cast aluminum at a constant temperature of 600 degrees.

 

 

We've begun to build up around the broken stud, laying layer over layer of the Super Alloy 5 into the gap.

 

 

After only 10 minutes of work and $49 of Super Alloy 5, this engine is ready to be cleaned up and re-installed.

 

Thanks Steve!

 

TIPS:

 

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.

 

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.

 

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) ..