Author Topic: Way yonder off topic- How to repair corrosion on the side of a aluminum intake  (Read 553 times)

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Offline JSOHC

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Got a rare 2X4 Dual plain Tunnelport intake with bad corrosion on one side and a little at the bottom of carburetor pad. It's pretty bad but not through. May be a 4 to 5" area. Any ideas? I know I can fill with devcon and etc. But I will have to paint the intake after I get through.
What say ye?
Thanks Jack in Ga.
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Offline sportyworty

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Weld
Grind
Repeat
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Offline redscj

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Weld
Grind
Repeat
     What he said. Corrosion in aluminium can worm hole deeper than you can see. At least remove the worst & fill with weld. Dress it down to match the expected contour. Fill the low areas & give it another go. I strongly suspect the intake is worth the work. Ford couldn't of made many of them.
Grant
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Offline LightWtJet

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I can acetylene weld steel but not aluminum. I believe it is hard to see when it puddles- what technique would one use? 
Is TIG easier to do in this case? 
Here is a TIG weld video-  he cautions this is not easy.
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Offline sportyworty

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Yes they Tig cast Aluminum. The choice of alloy filler is important. I had a Group II Cougar Manifold welded up by a professional.
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Offline preaction

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That is an awesome repair that guy did to the engine case in the above video he's  the kind of welder who can make a job look like its never been welded on.
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Offline jonw29

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Have you tried Lamar Walden in Doraville?
I am currently Cobra Jet-less.