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1967 Mustang Pot Metal Headlight Bucket 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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Received 11/9/2010:

 

Mike,

 

As you requested I attached a few pictures of the repairs I did on my 1967 Mustang Headlight Buckets using your kit.

 

Thanks, it worked out fairly well given I had not done this before.

 

Let me know if you need anything further.
Mike Rademacher

 

In this photo series, a 1967 Mustang headlight bucket is repaired by Mike Rademacher, a first time Muggy Weld customer. The pot metal has split or cracked, a common occurrance amongst these buckets. Mike cleaned the oxidation off first which is imperative before the solder process.

 

 

Cleaning both sides of the pot metal and grinding the crack to remove all oxidation is the best way to prepare the part. Note: Prep metal just before soldering.

 

 

Notice the smooth fillet when using the Super Alloy 1. You can achieve these results every time if you dont overheat and add the flux when you add the rod.

 

 

If the part was heated from the bottom, the Super Alloy 1 would have pulled through and filled the crack without needing to turn it over to finish the other side.

 

 

After grinding or sanding you cannot tell the difference between Alloy 1 and the pot metal. Another perfect repair without ruining Mike's original Ford Mustang headlight bucket.

 

 

Great job Mike, and thank you for submitting your photos and proving why our Super Alloy 1 is the most popular and easiest to use pot metal solder on the market!

 

 

TIPS:

 

Dont throw away repairable parts--use the same product these shops use, and make these repairs for a fraction of the price.

 

Do no apply heat to the rod itself, broadly heat around the rod to improve flow.

 

Super Alloy 1 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) ..