Thanks Thanks:  0
Likes Likes:  0
Needs Pictures Needs Pictures:  0
Picture(s) thanks Picture(s) thanks:  0
Results 1 to 5 of 5
  1. #1
    Join Date
    Oct 2011
    Location
    Norwood-ish, Adelaide
    Age
    59
    Posts
    6,540

    Default Tips for welding in a narrow space (gap)

    I volunteered to try to repair an aluminium step pulley (A series) that had part of the flange cracked off
    P1040374.JPG
    I did it by smoothing out the break, cutting a bit of sheet to suit, welding up and then machining the profile back. It sort of worked - the first go was a bit ropy (below) so tried again and was a little more successful
    P1040379.JPG
    I suspect that the alloy was a casting alloy so the higher silicon would not help, but I did have trouble getting a good bead in between the flanges. I tried switching to a gas lens, and that helped cover the longer than usual stick out that I had to use, but would be interested to know from members who have done this sort of thing before if there was a better/ more reliable/ easier way of doing this.
    Plan B was to machine the whole flange off and weld a new one on, but I suspect that although the welding would be easier, the wedging action of the belt would cause problems down the track.
    Thanks, Michael

  2. #2
    Join Date
    Nov 2007
    Location
    melbourne australia
    Posts
    3,228

    Default

    Quote Originally Posted by Michael G View Post
    Plan B was to machine the whole flange off and weld a new one on, but I suspect that although the welding would be easier, the wedging action of the belt would cause problems down the track.
    Someone on the forum (Anorak Bob?) repaired a stepped pulley by machining up a new pulley section with a hub/boss on it and then pressed it into a matching hole in the original pulley with some Loctite bearing retaining fluid.
    Chris

  3. #3
    Join Date
    Aug 2008
    Location
    Adelaide
    Age
    68
    Posts
    1,373

    Default

    I have heard of people heating the tungsten and putting a slight bend in it to aim the arc better but have never tried it myself.

  4. #4
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    71
    Posts
    5,942

    Default

    If it were me, I'd fill it completely by TIG welding the break out. The excess can be machined out, and you'll have a smooth finish. Kryn
    To grow old is mandatory, growing up is optional.

  5. #5
    Join Date
    Oct 2011
    Location
    Norwood-ish, Adelaide
    Age
    59
    Posts
    6,540

    Default

    I was a bit concerned about how much heat would be needed to do that. The large missing piece was 5mm thick and 20mm wide - a lot of molten metal in a small space. Would probably distort the flange.

    Michael

Similar Threads

  1. Welding Tips and Tricks
    By Blu_Rock in forum WELDING
    Replies: 6
    Last Post: 31st Jan 2016, 01:06 PM
  2. CIG Colt welding tips
    By Gavin Newman in forum WELDING
    Replies: 3
    Last Post: 10th Dec 2010, 01:19 PM
  3. CIG Colt welding tips
    By Gavin Newman in forum METALWORK - Machinery, Equipment, MARKET
    Replies: 0
    Last Post: 6th Dec 2010, 10:04 PM
  4. Tips and tricks for welding
    By matthew_g in forum METALWORK GENERAL
    Replies: 1
    Last Post: 10th Jun 2010, 12:38 AM
  5. Hobart Welding Tips
    By wheelinround in forum METALWORK GENERAL
    Replies: 0
    Last Post: 20th Aug 2009, 02:11 PM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •