How To Weld Hole On Block - Exhaust Separator

[boatmon345]

Rebuilding 1997 Yamaha 150HP 2 stroke S150TXRV powerhead.<br />( Click here to view updated blog with new pictures )<br /><br />Pressure cleaned the block today which I later discovered a 1/4" chunk was missing from exhaust separator on block. This missing chunk is part of a mating surface. Click here for picture. <br /><br />I welded a copper pipe once or twice. Can I weld this myself? What kind of torch do I need? I've got handheld MAPP and PROPANE torches. Machinist can do it for labor charge, but maybe I can spend that amount on a suitable welder <br />and git-r-done.<br /><br />HELP. Thanks a bunch.

 

[rodbolt]

Re: How To Weld Hole On Block - Exhaust Separator

aint gonna happen.<br /> find the best aluminium welder and pay him double.<br /> however most saltwater blocks dont weld well. the salt is in the pores and contaminates the weld leaving pin holes.<br /> AL must be gas shielded from the atmosphere when welded.

 

[Ray Neudecker]

Re: How To Weld Hole On Block - Exhaust Separator

Personally, that block would have gone to the recycle place already. Trying to weld a corroded block and keep it from leaking is most often an exercise in futility which becomes very expensive when water leaks through it and destroys parts.<br /> As rodbolt pointed out, the best of welders with the best of equiptment can not often make that weld seal properly.