Mike, I have to tell you that your 77 cast iron electrodes are fantastic--I need to order more to have it on hand.
I just welded a small block Chevy 400 engine with a broken ear on the starter mount. The engine was sitting on a 3 wheel engine stand and fell over breaking the mount. I placed a mild steel bolt in the broken mounting hole and built the whole corner back up, then I removed the bolt and re-tapped the bolt hole with no problem. It's looking pretty good.
I work on hard to find and restore irreplaceable antique cast iron parts. Your 77 welding rods are better than anything I've tried in the past. I'll try to remember to send you photos of my next cast iron job.
Super Alloy 5 is the simplest aluminum torch repair ever developed!
|Super Alloy 5|
|Melting temperature||600° F|
|Bonding strength||30,000 PSI|
|Sizes available||3/32", 1/16"|
|Recommended torch||Propane, MAPP, oxyacetylene|
|Can weld thick aluminum?||Yes with oxyacetylene|
|Can join aluminum to other metals?||No|
|Can repair cast aluminum?||Yes|
|Can be used with TIG?||Yes|
|Can be plated?||Yes|
|Can be polished?||Excellent|
|Takes powder coating?||Excellent|
|Can repair aluminum boats?||Yes with oxyacetylene|
Aluminum welding is a good way to repair or create new items. Although an aluminum weld requires skill and a careful hand, a high quality aluminum torch repair product can allow you to easily create durable bonds.
Before working on the metal, make sure to clean it first using a wire brush to remove the dirt and grease. Pre-cleaning the metal will also help you to use less flux. Secure the aluminum in place and ignite the flame on your torch until a soft, blue flame appears. Next, heat up the flux and coat the tip of the part you're bonding with flux.
You don’t have to worry about heating up the metal too much when performing repairs using Super Alloy 5 because it bonds at half the melting point of aluminum, and even through paint, oil, dirt, grease.
Finally, let the metal cool naturally, then remove the flux with warm water and a wire brush . When it's ready, you can use a sanding disc, Dremel tool, or sandpaper etc to smooth the metal.
For more information on Super Alloy 5 and to watch instructional videos, click the links below:
An aluminum hood molding is repaired with Super Alloy 5.
Brazing 3003 Aluminum with Super Alloy 5
Brazing Aluminized Stainless Steel with Super Alloy 5
We are brazing two thin aluminum plates at over 30,000 PSI using Super Alloy 5 rod and flux. First wire brush your aluminum to remove the oxides, broadly heat your base metal and add your flux with the torch.
Demonstration of how to fix two holes in an aluminum air conditioning tube with Super Alloy 5 rod and flux. One of the holes has not been cleaned before soldering or brazing.
Demonstration of the strength of Super Alloy 5--we soldered two aluminum plates together only using a very small amount of rod and flux. John of (John Barrett Works) invited us up to his shop to assist with some aluminum brazing and was also kind enough to hold the camera while the soldering was taking place.
In this video clip, Mike fills a dime-sized hole in aluminum with Super Alloy 5 and an oxyacetylene torch.
2 plates side by side demonstrating how to fill gaps in aluminum with Super Alloy 5.
After joining 2 aluminum plates we put the strength of Super Alloy 5 to the test. Watch as the plates are put into a vice, as well as an attempt at pulling the plates apart with pliers.
A 7 inch cut in an aluminum bumper reinforcement is welded with Super Alloy 5. We have posted this video at a sped up rate due to the length of the repair.
Often we are asked whether or not Super Alloy 5 can join thick pieces of aluminum to thin pieces. In this clip we join a heavy section of aluminum to a thin piece of tubing using an oxyacetylene torch.
This Toyota Land Cruiser cast aluminum intake manifold had a 3 inch cut across it. Super Alloy 5 is ideal for fixing cast aluminum, so we used an oxyacetylene torch to make the repair. We recommend using oxy-acetylene on all thicker aluminum because it can sometimes be difficult to keep the base metal at the correct temperature with propane or MAPP gas.
A cracked cast aluminum transmission case is repaired with Super Alloy 5 and an oxyacetylene torch. Due to the thickness of the aluminum, we recommend using oxy-acetylene and a size 3 or 4 tip. Once you get the cast to the proper working temperature, the aluminum filler rod flows in wonderfully.
This clip shows how to join aluminum a/c fittings using the same material thousands of auto repair shops and auto air conditioning shops use daily. It is no longer necessary to wait up to a month for replacement parts for your a/c system. Super Alloy 5 is a quick, inexpensive solution to all your a/c problems, enabling you to make aluminum repairs yourself.
We are welding an aluminum return loop with Super Alloy 5. Notice the filler rod's perfect color match in comparison with the parent metal--you cannot see the difference.
2 aluminum plates being welded with Super Alloy 5. This demonstrates the flow of Super Alloy 5 as well as the capillary action (flow from front to back, side to side)
In this clip: how to determine when to use propane and when to use oxyacetylene when repairing aluminum. Soldering vs. Brazing.
This clip is especially for ATV owners. It demonstrates an aluminum radiator being repaired repaired from a vertical angle with our Super Alloy 5 and an oxyacetylene torch. If you can get to the damaged area with a torch you can fix it without removing it from the ATV.
Mike demonstrates how to weld a radiator in the vertical position. The 10 year old aluminum part has not been pre-cleaned of the dirt, oil, grease etc. A great example of why you need a separate flux when brazing aluminum.
We are joining 2 pieces of aluminum tubing--just another view of how to weld differing thicknesses of aluminum together.
An Aluminum boat is riddled with holes from corrosion from salt water. Steve is a first time muggyweld.com customer using the Super Alloy 5 and an oxyacetylene torch to make the repairs.
Steve at Alternative Automotive makes a repair on a very corroded portion of his aluminum boat.
Demonstration of how to protect your heat sensitive surfaces without disassembling your parts.
This is a 1997 Ford F150 aluminum cylinder head with corrosion eating right through the aluminum. The replacement cost for this part was $2200.
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.
This diesel Tow Truck jack-knived and ripped a cut into this aluminum hydraulic oil tank. This rig couldn't wait two weeks for a replacement tank on order.
A 1993 Acura Integra odometer gear pickup needs reattached.
This Ford Ranger 2.9 L intake manifold had a broken EGR valve mount.
This cast aluminum 2.2 liter engine block came off a 1996 Honda Accord that had been involved in a minor traffic accident.
Repairing a brand new Ford Tractor's transmission cooler, customer accidentally ripped the aluminum while tightening.
This antique weather vane was damaged in the recent Gulf Coast hurricanes.
Heat protection really comes into play when metal parts are connected to or close to heat sensitive surfaces such as glass, rubber, paint, chrome, plastic etc.
Mike repairs an aluminum boat with Super Alloy 5.