Well my luck just keeps getting better:

[tryanATTAK]

I was removing my tunnel protectors by using my die grinder to expose the rivets and then attempting to chisel the rivets off and as my luck would have it one of the rivets in the bulkhead under the exhaust pulled right through the bulkhead breaking it open around the rivet to the size of alittle bigger than a dime. The rest of them came off cleanly. So what am I to do now? I can't get it to a welder as the whole sled is tore apart. I have the 2 pieces that came out and thought about just JB welding them back in but not sure if that would be strong enough to prevent it from cracking further. I might just have to go get some pure Argon and try welding it myself. I do have a MIG welder but it's just a Hobart Handler 140. Any suggestions? I was following what others here have said they did to remove the protectors and for the most part it wa easy but this one rivet instead of cutting off pulled through the bulkhead. Maybe it was cracked to begin with but who knows.

 

[bashley]

Is it in a spot where you can sandwich some plate to it? Maybe even bolt them on if it's too long for rivets. It should be plenty strong if they'll fit.

 

[tryanATTAK]

I also thought about doing this but my concern is if I don't weld it up that it will continue to crack. I was thinking if I could weld it up then I could take one of the tunnel protectors and cut it so I would be using just one of the four sides and weld that to the bulkhead also as a backing plate. Still trying to find out if one of my buddies has pure Argon.

 

[The Artist]

You could drill a hole a little bigger the crack where it is cracked to stop the crack, then drill new hole for the rivet in the bulkhead and protector

 

[tryanATTAK]

I'm not going to use the protectors I'm taking them out for clearance for my new 151x15x2.25" track. I finally got hold of one of my buddies and he said he'll either get here tomorrow or Monday to weld it up for me. It just figures I would have this happen the rivets at the back of the protectors were so loose I could just pull them off they came right out of the protector. this one rivet was the only problem one.

 

[grizztracks]

even when welding the crack it is best to drill the ends of the crack to prevent future cracking.

 

[pro116]

Weld it.I did the same thing and after the end of the year my whole back end busted off.

 

[tryanATTAK]

Weld it.I did the same thing and after the end of the year my whole back end busted off.

Mine is at the front of the tunnel right underneath the exhaust pipes and under the exhaust heat shield. It's in the area where there is actually 3 layers one being the bottom cast, the middle layer the heat shielding, and the top being cast again. I'm thinking it might have been cracked to begin with but I don't know for sure. The back rivets were tight in the diecast aluminum but were loose in the protector to the point I just pulled the protector right off the rivet then cut off the rivet. but the front ones were tight so I ground down the protector tube until the rivet was exposed and tried to chisel it off, and that's when it pulled right through the diecast creating about a dime sized hole. After that I just gound off the rest of the rivets, which is what I guess I should have done in the first place. That's what happens when you get in a hurry I guess. I have read on here that some guys have used an air chisel and others have just chiseled them off with a cold chisel and hammer. Oh well hope it holds up.

 

[tryanATTAK]

Well we tried repairing the hole to no avail. We did drill holes at the ends of the cracks and got those filled and the cracks welded up but we could not fill the hole itself we did not have a high frequency TIG welder as we were having some problems maintaining proper flow. I'm just about to give up on this project and everything else also. With the cracks drilled and welded do you guys think it will hurt anything to just fill the hole with JB weld and call it good?

 

[tryanATTAK]

ttt

 

[sherlock29]

If you need to repair aluminum and cant weld it... i was told by a few welders that JB weld is not too good... I work in industry and we us this stuff called dextron alunimum putty... its a 2 part mix, and when it hardens up its fully machinable. We have used it here on bearing housings, pump and motor shafts etc... its stronger than aluminum and i actually have it on my front rad where i put a stud thru... holds great!!! its expensive tho... around $75 bucks for a 1 lb container(smallest size). I have now used it a few times with great success.

 

[rxrider]

Drill out the missing area with a suitable hole saw drill bit, there will be no cracking in the future. Patch the hole up with some black silicone and an aluminum plate and rivet it in, it will never come loose because of the silicone. You will have to chisel the alu piece out if you'll ever have to remove it. Almost as good as welding the hole shut.