Welding Ford FE Cobra Jet VC's

[Movin/on]

I bought these VC's quite a few years ago and now want to repair them to as close to original in appearance as I can.
They seen to be Diecast and some have been welded, but I'm not sure of the method used. (gas, MIG or TIG). Are these salvable and how could I repair them. I've got both a MIG and TIG welder. My Miller TIG is a Syncrowave 210.
Movin/on

 

[joe_padavano]

They're just aluminum. They were welded once when those tubes were added. TIG is the way to go. Be sure to get the weld area REALLY clean.

 

[jabberwoki]

Yep I did some old Edelbrock aluminum Buick valve covers that way.
Worked like a champ.
Got to be ****** spotless clean as mentioned.

 

[kabinenroller]

Use tig but bolt them to a head while welding. Aluminum will move all over the place when heat is applied while welding.

 

[readhead]

Clean with a stainless steel brush. If you clean with a steel brush you will never want to weld again.

 

[no704]

Might be a good idea to cook them for awhile to out gas any old oil that may have snuck in?

 

[Monza Harry]

Well they have been welded before so they definitely can be welded. The above responses are all spot on! I particularly like the responses about giving them some time at temp to persuade the absorbed oil to leave and the bolt them to a head (a really heavy plate would likely be ok then clamped [gently between the screws, especially towards the ends]) suggestion. Harry

Might be a good idea to cook them for awhile to out gas any old oil that may have snuck in?

Use tig but bolt them to a head while welding. Aluminum will move all over the place when heat is applied while welding.

 

[welder4956]

Those are definitely repairable and TIG is the best choice. Your Miller Syncrowave 210 is perfect for this job, but how are your aluminum TIG skills? The inside corner fillet weld of the tube welded to the side of the cover will be somewhat difficult to keep from overheating and blowing through, but can be done. It would be helpful to practice this joint on some aluminum sheet the same thickness as the side of the valve cover and a short piece of tube. That would allow you to refine your technique and current setting, and then give you a better result if you are not confident in your aluminum TIG skills.

 

[Ohmthis]

Exactly what needs to be repaired? All the advice is spot on so far. You cannot over clean this type of job. Scrub with a SS brush. Use a heavy solvent like acetone and wipe everything down. Then scrub some more and repeat with the solvent. The outer skin of aluminum is harder than the actual metal and melts at a higher temp. This must be brushed off. You’ll know when you have cleaned it off when the metal gets soft and really grips the brush.

 

[txvwnut]

I’ll add that when you get ready to do the weld repair pre-heat and post heat. I’ve made the mistake of doing cast without pre and post heat and listened to it crack while cooling.

 

[TimeWarpF100]

I bought these VC's quite a few years ago and now want to repair them to as close to original in appearance as I can.
They seen to be Diecast and some have been welded, but I'm not sure of the method used. (gas, MIG or TIG). Are these salvable and how could I repair them. I've got both a MIG and TIG welder. My Miller TIG is a Syncrowave 210.
Movin/on

I have welded many CJ covers thru the years. Both 428 and 429 style. It's been a while though. Probably 10 plus years on the last pair. I used TIG

 

[Movin/on]

Exactly what needs to be repaired? All the advice is spot on so far. You cannot over clean this type of job. Scrub with a SS brush. Use a heavy solvent like acetone and wipe everything down. Then scrub some more and repeat with the solvent. The outer skin of aluminum is harder than the actual metal and melts at a higher temp. This must be brushed off. You’ll know when you have cleaned it off when the metal gets soft and really grips the brush.

I want to plug and fill the holes. I'll weld a thicker piece of aluminum (next gage size up) into the hole flush with the outside of the VC.
Movin/on