Hey guy's recently picked up a outboard engine for my new boat, the outboard had water in one cylinder so first thing i got the outboard off the truck and onto the boat and took the head off for inspection

I found the cylinder head had a previous weld job that was very poor there was a corroded hole from one water gallery straight into the combustion chamber it had been mig welded poorly the blob of weld just broke away with a screw driver

It took some cleaning first i soda blasted the cylinder it done minimal cleaning than i used a gasket spray remover than i finally pressure washed the head and water galleries, the pressure washer worked fantastic for removing all the calcium and shells inside the galleries

Now i die grinded all the corrosion back to fresh aluminium, gave all the grounded area's a whiz with a tiny stainless steel brush, than placed the head in the oven the over was set to 100 celcius but using a thermometer it only reached 54 celcius so i took it out and began to weld

My eye sight is poor so i dabbed the 4043 filler rod to much in places but i'll show the flatter welds

Turned out perfect with a quick ryobi die grind only 1 weld had a small amount of pourosity

Keep in mind i'm only using a cheap $400 Edisons ac/dc 160amp tig 2 dials 1 being amp the other being cleaning

I put to practice all the help you guy's have given me over the year's a big one was to wipe the new filler rod's which i did and they were very dirty straight from the shop in a bag in a box, also i started at 90amp but i was'nt getting a pool so bumped the amp to 102amp and worked perfect very managable pool without blowing out side walls on the head
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