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Begin practicing on a small throw-away piece (thermostat housing or a chunk of bell
housing).
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Be prepared to make some mistakes while learning.
Ø
Always wear dark glasses
when repairing any kind of aluminum with an oxy-acetylene torch because the acetylene
and flux combine to give off yellow/orange color.
Ø
Always use oxy-acetylene
when repairing cast aluminum.
Use a #2-#4 tip (practice with each) and a 1/4" blue flame. Crank the oxygen
(much "hissing") at first.
Ø
While holding fluxed rod at the ready, preheat beginning of repair area. Keep
the heat in one place until skin of aluminum begins to "dimple" or change color.
Bring fluxed rod in so it touches aluminum. Work tip of rod with flame.
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If the rod balls up upon touching aluminum, it means the cast is not yet hot enough
to pull in the rod material, so take the rod away and do some more pre-heating.
Ø
Reflux the
rod. Bring it back in.
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When the rod begins to flow ("puddle" on cast aluminum), take the torch away and
turn the oxygen down for greater control.
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Now pick up some more flux and come back in with the rod--then flame. Take a little
deposit off rod and flow it out.
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Continue repeating these steps - melt flux and a little deposit off rod, flow deposit
out, take heat away, reflux rod, melt flux and a little deposit off rod, flow out
deposit, take flame away, reflux...and so on until repair is complete.
Ø
Using a backing plate can help prevent sagging.
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If you are willing to do a bit of patient practicing, you can become a master cast
aluminum repair person.
Ø
Which means you will be a master at repairing virtually any kind of metal because
cast/magnesium aluminum is the only metal that is even
slightly difficult using Alloys #1, #5 or #6.
Ø
All repairs are totally machinable (see Alloy #5 example page).
Ø Whenever repairing cast aluminum, be sure to use a snugly
fitting malleable copper backing plate. Just clamp it in place until the repair
is completed. This way, you can use plenty of heat without worrying about
the cast sagging away. Simply build up again any spots that have dimpled.