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Old January 25th, 2012, 10:54 PM   #1
JACK48461
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welding cast?

Here's my little dilema. I'm almost done building my 2.8l for my samurai and forgot about the one exhaust stud that was snapped flush into the head. Not to big of a problem at first figured i'd drill it out pb blaster it for a few nights and heat/repeated for 3 days before attemping to remove it. Then the extractor was starting to spin it maybe 1/8 turn in the whole and it also snapped and it put a crack in the cast. This stud cracked on a raised boss that will not effect anything on the motor. Here's m problem though i cut thru the crack with a die grinder to relieve the pressure on the stud. it's out now the theads are all there except for the cut line but what do you think i should do? I can & i think its my best way to go weld the entire whole and cast. Then deck the bolt surface redrill an retap. Has any one else ever welded cast and done this? Do you think it'll hold about 30 ftlbs on & the exhaust temp?
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Old January 25th, 2012, 11:44 PM   #2
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Ya go ahead. You just need to heat the cast before you weld it and have a control cool as in heating it and slowly dropping the temp.

FYI you can not mug weld it. Arc weld only
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Old January 25th, 2012, 11:48 PM   #3
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Ya go ahead. You just need to heat the cast before you weld it and have a control cool as in heating it and slowly dropping the temp.

FYI you can not mug weld it. Arc weld only
I weld cast all the time with a MIG welder. Preheat, short bead, stress relieve with a center punch, repeat. I make sure to keep my welding area warm when I'm not welding. Slow cool, done.
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Old January 25th, 2012, 11:48 PM   #4
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Arc weld with nickel rod...

(nomacast from napa)
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Old January 25th, 2012, 11:52 PM   #5
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I weld cast all the time with a MIG welder. Preheat, short bead, stress relieve with a center punch, repeat. I make sure to keep my welding area warm when I'm not welding. Slow cool, done.
I have no had no experience welding cast with other then an arc welder. When I went to school for welding they all said not to do it besides with an arc welder.

I wouldn't do it with a mig



Beefy is correct. I couldn't remember what it was of the top of my head.
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Old January 26th, 2012, 01:18 AM   #6
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Preheat, arc weld with nickel rod, stress relieve with a punch between every pass, let it cool very slowly. Wrap it with fiberglass insulation to make it cool as slow as possible. Heat up a fairly large area around where you weld so it takes more time to get rid of the heat also.
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Old January 26th, 2012, 06:42 AM   #7
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i think i would put a stud in it, weld up the crack, and if the stud cant be removed than just use it. they make a crayon that wont melt until your cast is up to temp, you should get one of those, if a heat checking gun isnt available.
i have welded on cast with a mig and it held.
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Old January 26th, 2012, 07:20 AM   #8
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I'm pry going to have try the stud idea i have threads and it holds a bolt great. I just haven"t tried putting a header on and torqing it down. Next issue i only own a mig i've never arc welded nore do i own one. That being said how do you guys feel on the stud thought? Best tips to make this work and hold? Worst case i fukc it all up and pull the head and buy a new one
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Old January 26th, 2012, 08:16 AM   #9
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These guys makes some high nickel MIG wire, I think. But its really pricy.

http://www.crownalloys.com/products.php
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Old January 26th, 2012, 08:48 AM   #10
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Thanks ill check it out i can get welding supplies thru my work cheap i'll see what i can get. So the key is im assuming to get a high nickel wire
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Old January 26th, 2012, 10:17 AM   #11
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Thanks ill check it out i can get welding supplies thru my work cheap i'll see what i can get. So the key is im assuming to get a high nickel wire
i think more important is the temp of your material, it will need to be heated before, during, and after welding, to slow down cooling.
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Old January 26th, 2012, 10:22 AM   #12
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I have had good luck with a mig with flux wire and heat!
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Old January 26th, 2012, 10:36 AM   #13
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ive had good luck using nickel rod and heat.
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Old January 26th, 2012, 10:36 AM   #14
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So many options lol. There is a mobile welder thats very good out my way who wants $100 to come out and do it i may just go that way bc he's been welding cast for a long time and it's always been my experience lately that the cheaper i try to be the more it ends up costing me so idk. I've been pricing out the nickel mig wire thinking I can attempt this but the place by me sells it but it's $80 for a 2lb spool so for $20 more i can pay someone to do it. Would you just pay to have it done or just order the spool?
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Old January 26th, 2012, 11:10 AM   #15
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If its $100 to have the guy come out and your worried about being able to weld the cast successfully I would pay the $100.
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Old January 26th, 2012, 11:48 AM   #16
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If its $100 to have the guy come out and your worried about being able to weld the cast successfully I would pay the $100.
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Old January 26th, 2012, 11:59 AM   #17
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He will be out monday to do it. I just wondered how hard it would be and if i can have it done right 1 time without tearing this down again id rather do that. If cast welded as easy as cold rold steel great but i rememberd ppl saying cast is tough to weld so thought id ask some opinions. Thanks for the help everyone
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Old January 26th, 2012, 01:00 PM   #18
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for $100 I would just buy a used head and never have to worry about the weld failing or the head being stressed.
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Old January 26th, 2012, 07:48 PM   #19
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for $100 I would just buy a used head and never have to worry about the weld failing or the head being stressed.
This.
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Old January 26th, 2012, 07:55 PM   #20
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I would probably epoxy or red thread locker the stud. No heat to stress the head and it should hold up just fine.
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