How To Weld A Cast Aluminum Bolt Hole Without Damaging Threads

Cast Aluminum Bolt Hole With Damage and Repaired Threads
How To Weld A Cast Aluminum Bolt Hole Without Damaging the Threads
 

Cast aluminum weld repairs are difficult. Welding around a bolt hole without damaging the threads is even more difficult. Here’s how to get it done quickly and easily using a simple trick with a stainless steel bolt.

Time needed: 30 minutes.

How to weld a cast aluminum bolt hole without damaging the threads.

  1. Clean and Degrease the area to be repaired.

    Clean area to be repaired with degreaser and wire brush.Cast aluminum before repair.

  2. Expose Bright Metal in cast aluminum.

    Use a carbide burr tool is to fully expose the bright metal.Cast aluminum with carbide burring tool applied.

  3. Remove Debris and Final Clean area to be repaired.

    Remove debris with compressed air and rinse area with acetone.Cast aluminum

  4. Pre-Heat with Torch

    This provides a mild pre-heat and ensures all grease and oils are cooked away.Cast aluminum

  5. Set Stainless Steel Bolt

    Thread Stainless Steel bolt into threaded area to be repaired.Stainless steel bolt threaded into cast aluminum before repair

  6. Make the Weld Repair

    Execute the repair, fully demonstrated in the video below…Cast aluminum weld repair

How to weld a cast aluminum bolt hole without damaging the threads demonstrated and clearly explained by The Fabrication Series from start-to-finish…

Knowing this quick Stainless steel bolt trick will probably save you on your next repair job!

 
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