Aluminum casting repair


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sunshineman6869
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Aluminum casting repair

Post by sunshineman6869 » Fri May 22, 2020 5:42 am



I managed to put a hole in one of my cylinder head covers, while trying to put insert in a striped out hole. I am thinking I need some JB Weld for aluminum, and I can put pieces back in place. What I am looking for is some suggestions for repairing this. I have an idea of how I will do it, but there are many more who have done this type of repair already and they may have some ideas for one to consider.
Thank you
Mike



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tamathumper
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Re: Aluminum casting repair

Post by tamathumper » Fri May 22, 2020 6:09 am

Depends on the size and location of the hole. Pics?
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Re: Aluminum casting repair

Post by Viking » Fri May 22, 2020 6:21 am

A good welding shop can repair aluminum. It may not be as pretty as before, but it will not leak. JB would be much less expensive, but will it be leak tight? Maybe.
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sunshineman6869
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Re: Aluminum casting repair

Post by sunshineman6869 » Fri May 22, 2020 6:40 am

tamathumper wrote:
Fri May 22, 2020 6:09 am
Depends on the size and location of the hole. Pics?


tamathumper wrote:
Fri May 22, 2020 6:09 am
Depends on the size and location of the hole. Pics?
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ct1500
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Re: Aluminum casting repair

Post by ct1500 » Fri May 22, 2020 8:03 am

I am thinking more like, just get a new valve cover. :!: More likely pot metal not aluminum.
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tamathumper
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Re: Aluminum casting repair

Post by tamathumper » Fri May 22, 2020 4:31 pm

Holy Christ in tights on a cracker... That's a hole you could throw a fixed cat through!

A new cover is what, $50? I'd go that route, unless you can get FlexSeal in aluminum color, and then I'd go that route, because you can make a high speed bass boat out of a screen door with that stuff. I've seen the infomercials...
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sunshineman6869
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Re: Aluminum casting repair

Post by sunshineman6869 » Fri May 22, 2020 6:12 pm

A replacement cover costs 282 dollars and some change

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offcenter
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Re: Aluminum casting repair

Post by offcenter » Fri May 22, 2020 7:05 pm

Lemmee tell ya a story...
50 years ago when I was a kid, my brother put a hole like that through the side cover
of a Kawasaki 350 he had. We fished the pieces out of the crankcase, cleaned them
up, and epoxied them back into place with PC-7 epoxy paste. He rode that bike for
two more years like that, then sold it to a friend who rode it another two or three
years!!.....with the patch still in place. This patch was in the crankcase of a two
stroke engine! And you know that with two strokes, the crankcase is pressurized!

DO YOU HAVE THE PIECES THAT BROKE OUT?
if so, find some PC-7 and patch it back together.
It will hold for a LONG time.

P.S. If you don't have the pieces, cut a piece of aluminum
flashing a little larger than the hole. Remove the valve cover
and clean around the hole inside and out to remove all traces of
oil, then epoxy the aluminum flashing on the inside. Then apply
a nice layer of that epoxy paste to the outside too.
Let it cure for at least a couple of days and put the cover back
on. You will be good to go!
George in Jersey.
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sunshineman6869
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Re: Aluminum casting repair

Post by sunshineman6869 » Fri May 22, 2020 8:30 pm

Thank you for the feedback. I am doing something similar to what you are saying, hoping I will see good results tomorrow

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Re: Aluminum casting repair

Post by MikeB » Fri May 22, 2020 8:47 pm

sunshineman6869 wrote:
Fri May 22, 2020 8:30 pm
Thank you for the feedback. I am doing something similar to what you are saying, hoping I will see good results tomorrow
Please let us know how it goes and include some pictures.
MikeB
Tacoma, WA, USA

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tamathumper
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Re: Aluminum casting repair

Post by tamathumper » Sat May 23, 2020 7:13 am

sunshineman6869 wrote:
Fri May 22, 2020 6:12 pm
A replacement cover costs 282 dollars and some change
A brand new one from Honda perhaps, but from the look of that photo a new one wouldn't match the rest of the bike. Lots of used ones with "patina" are available on eBay. Here's one for $85 or "Make an Offer".

https://www.ebay.com/itm/12-HONDA-GOLDW ... 8037!US!-1
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sunshineman6869
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Re: Aluminum casting repair

Post by sunshineman6869 » Sat May 23, 2020 11:01 am

MikeB wrote:
Fri May 22, 2020 8:47 pm
sunshineman6869 wrote:
Fri May 22, 2020 8:30 pm
Thank you for the feedback. I am doing something similar to what you are saying, hoping I will see good results tomorrow
Please let us know how it goes and include some pictures.
I just saw your email as I got back from a test ride of my fix, and there are no leaks, and I didn't take any pictures, didn't think I would need them, but I guess you never know. Basically I bought a 3' piece of 1" and 1/8" aluminum stock, cause I didn't have any, and cut off 3" and put that piece on the inside of the cover, it fit and covered the hole nicely and I used JB Marine Weld I think it was called, and let it sit for about 24 hours with a couple of C-clamps holding down the 3" aluminum piece to the cover and let it dry. I was surprised to see that the hole I was trying to get an insert into, was a dead hole, for lack of a better name. The bolt that went into this hole was stripped out, and my buddy doing the helicoil repair said he would have to go 2 size to get a helicoil to fit, and he wasn't sure if there was enough "wall" to be strong enough. The bolts in these 2 lower holes look like they keep the chrome trim piece that say "HONDA" attached, but double side tape is what was keeping my chrome strip attached. Those 2 holes did nothing except house a place for the chrome bolts, nothing functional that I could see.
That will have to do for pictures, sorry
MIke

sunshineman6869
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Re: Aluminum casting repair

Post by sunshineman6869 » Sat May 23, 2020 11:05 am

tamathumper wrote:
Sat May 23, 2020 7:13 am
sunshineman6869 wrote:
Fri May 22, 2020 6:12 pm
A replacement cover costs 282 dollars and some change
A brand new one from Honda perhaps, but from the look of that photo a new one wouldn't match the rest of the bike. Lots of used ones with "patina" are available on eBay. Here's one for $85 or "Make an Offer".

https://www.ebay.com/itm/12-HONDA-GOLDW ... 8037!US!-1
Thank you for that info
Mike



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