cast mailbox decor fix question

[keith524]

hey fellas, its been awhile since I have posted, dang snow is killin me! anyways, my uncle has his own business doing snow removal in the winter and a customer is saying that he or one of his employees broke the mailbox décor off. picture posted.

Mofab, a huge fab shop quoted him 500.00 to fix it. im guessing for them to go to the site and tig, or braze it....

I have torches, and all the goodies, my Tig welder is nowhere close to portable though. would it be easier for him to just buy and install a new one? or for me to braze it or pay mofab 500.00 to fix it?

thanks for the advice guys. he is taking a picture of the rest and sending it to me. ill repost those pics asap!

 

[Kevin54]

You may not be able to buy that and replace it if it is antique wrought iron. Tell him to bring it to you or send it to you and weld it back together if he has the extra pieces.

Those sort of look like the same ones my dad had on his house, which I took down, but sadly I gave them all to my son or I would send you one. You may be able to find one close to it at some of the antique stores if you have any around. Wrought Iron was fairly popular way back, and people have removed it to replace with more modern pieces. A lot of those corner brackets are used to make shelves out of.

 

[Bondo]

Ayuh,..... Is it cast iron, or zink,..??

I'm thinkin' there ain't gonna be any weldin' that'll fix it,...

If it's cast iron, maybe braze, or nickle gas weld it,...

 

[iamironman]

If it is cast iron, (most grades anyway) and is NOT a structural item, but purely ornamental, you may be able to mig (GMAW) weld it, too.

While not one of the best methods it is doable with a little care. Preheating and stress relieving (gently peening immediately after welding) and slow cooling, either in an oven or large enough container of sand, or vermiculite, will help increase your odds of success.

As previously stated, SMAW welding with nickel rod should work well, too. (Actually this is a better option than GMAW, and better suited to on-site work that GTAW)

If it is zink, or another grade of "pot metal" forget welding altogether and replace it.

If you decide to try replacement instead of repair King Architectural Metals is a good place to start.

Similar item: http://www.kingmetals.com/Catalog/ItemContent.aspx?ItemNumber=5345&CatalogId=C39&CatalogDetailId=111

(pretty cheap, too all things considered this may be your cheapest alternative. I know if you brought that to my shop by the time you preheat, weld, grind smooth it'd be at least a hour labor.)

 

[keith524]

ok thanks fellas for the quick response! the bad thing is, this is what my uncle said anyway, is that the other piece is actually welded to the post that is concreted into the ground, which unless taken up, would be hell to preheat outside in this weather... im not sure of what exact metal it is right yet, looks like wrought iron to me.... I ground down one of the welds on the piece I do have and looks to be welded, or atleast its not the gold color like its been brazed.
I am thinking it would be cheaper for him to just replace the whole thing!

 

[iamironman]

ok thanks fellas for the quick response! the bad thing is, this is what my uncle said anyway, is that the other piece is actually welded to the post that is concreted into the ground, which unless taken up, would be hell to preheat outside in this weather... im not sure of what exact metal it is right yet, looks like wrought iron to me.... I ground down one of the welds on the piece I do have and looks to be welded, or atleast its not the gold color like its been brazed.
I am thinking it would be cheaper for him to just replace the whole thing!

If you have the o/a set and can get a helper to preheat while you're ready and waiting to weld it should be no problem. In a pinch a small part like that can sometimes be welded successfully without the preheat.

While I can only guess by your pics I'd be willing to bet it is cast iron, it's a very common material for those castings.

If you have a stick welder (and associated skills) available get some nickel rod and weld that bad boy. It's really not a big deal as long as the item is just decorative.

Get your uncle to buy the consumables and tell him to pay you the difference between that and what the "big shop" wants.

Seriously don't be scared, it's just metal. Worst case if you try and fail you're only out the time and consumables.

 

[keith524]

ok thanks for the advice! I will let him know what the deal is! I appreciate all the help gentlemen!

 

[kbs2244]

brazing??

 

[Bondo]

brazing??

Ayuh,... In the situation that's been stated, Ya, Braze it together,...

It ain't gotta be brazed at All the breaks, just a couple to hold it together,...

 

[keith524]

I do believe, with the situation at hand, that I am going to braze it. I sold my small stick welder and now I only have a very big one. plus, I would have to have a generator to run one either way. I do believe I will have to go that way.....


that is now my stick and tig welder. lol. I wasn't thinking when I sold the small stick welder. I suppose one of these days I will have to get a miller welder/generator!