Anyone done any welding to their apexes?

[mulderdad]

Like some of you know I had a pretty good accident a week or so ago and have a broken apex.
The lower left side a-arm was broke right out of the aluminum bulkhead.
Actually only about have of the lower front hole was broke off and the other half is still good. My question is if I get this welded and filled solid with aluminum and re-drill it, will it be as strong as before? I am planning on getting it welded up within a couple weeks and built up on the outside a little thicker, then I'll re-drill the hole for the a-arm.
OR Should I just by the front left half of the bulk head and change it over the summer? I was hoping the welding would work to save a lot of time.
Any comments or thought are greatly appreciated.
Thanks,
Rick.

 

[LazyBastard]

Almost. I wouldn't trust it to be quite as strong as before, BUT, you have two sides of the sled that are pulling apart. You can always tie them together with a strap, turnbuckle, etc. I've suggested it before, and someone actually did it and it worked out very well. Much cheaper than replacing the bulkhead, and stronger than original.

 

[berge75]

Weld it,then make a supprt plate to tie both left and right bolts together. Do a search,somebody has pics of one that was done on here.

 

[mulderdad]

I just found the post you are talkin about. It looks like it would work. I was looking over my apex and would have to remove A LOT of rivets to get the bulkhead off.
Thanks,
Rick.

 

[Iceman57]

If a weld is correctly done, it will be stronger then the original metal that is being welded. For instance, the tubes for axel housings start out as a flat plate. The plate is curled up through a machine until the two half’s come together making a long pipe. The seam of the pipe is then welded together by a machine. When quality control does their tests on the tube they use a machine that jams a cone into the end of the tube until the tube splits. If it was welded correctly the tube will split anywhere but the weld, if the tube splits at the weld during the test it reveals a problem with the welder and adjustments need to be made. A reputable welder should be able to properly fix your bulkhead.

 

[mulderdad]

Thanks guys, I'm gonna do like you said and weld it then brace it.
Cheers,
Rick.

 

[RJH]

disconnect all electrical stuff - first.

Just to be safe.

 

[apltx08]

Try this guy I beleive he has what you need...

http://www.ty4stroke.com/viewtopic.php? ... highlight=

 

[LazyBastard]

If a weld is correctly done, it will be stronger then the original metal that is being welded. For instance, the tubes for axel housings start out as a flat plate. The plate is curled up through a machine until the two half’s come together making a long pipe. The seam of the pipe is then welded together by a machine. When quality control does their tests on the tube they use a machine that jams a cone into the end of the tube until the tube splits. If it was welded correctly the tube will split anywhere but the weld, if the tube splits at the weld during the test it reveals a problem with the welder and adjustments need to be made. A reputable welder should be able to properly fix your bulkhead.

He's talking about welding the cast aluminum bulkhead.

 

[**sj**]

make sure you disconnect the electrical boxes first...

 

[Iceman57]

He's talking about welding the cast aluminum bulkhead.

Yea....so am I. You can Mig or Tig (Tig the better method) and you can even use HTS-2000 Brazing Rods or Alumaloy welding rods. The key is to preheat the Aluminum properly before starting, 350 to 400 degrees. And again....you need to find a good welder with plenty of experience.

 

[LazyBastard]

And you can NEVER make it stronger than the original cast without completely replacing all remnants of the original cast, which means that more than likely (unless the job done is PERFECT), it will be weaker than stock.

BTW: You were talking about welding steel tubes, which are pliable. The aluminum bulkhead is brittle

 

[Iceman57]

And you can NEVER make it stronger than the original cast without completely replacing all remnants of the original cast, which means that more than likely (unless the job done is PERFECT), it will be weaker than stock.

BTW: You were talking about welding steel tubes, which are pliable. The aluminum bulkhead is brittle

The tubes were just an example. Obviously you don’t know much about welding cast aluminum. Call any reputable welding shop (248-435-2730 for instance) and they will tell you cast aluminum can be welded to be as strong as the original cast or stronger. My brother in law has been a welder for 35 years and welds cast aluminum almost on a weekly basis. He does a lot of cast aluminum bell housings as well as transmissions for many trans. shops in our area. He does a lot of welding on our dune buggies especially the transmissions, engine blocks and bell housings. Never once has one of his cast aluminum welds broken. The same part may have broken but in a different place other then his weld. He said he would be glad to give you a welding lesson if your ever in the area.

 

[blurred vision]

We had a new 03 rx1 in 03 that hit a ditch and the ear was broken off on the bulk head. We welded it in 03 and 10000 miles later its perfect still today. Welded right and theres no problem.

 

[Iceman57]

We had a new 03 rx1 in 03 that hit a ditch and the ear was broken off on the bulk head. We welded it in 03 and 10000 miles later its perfect still today. Welded right and theres no problem.

What he said