Racing Puma inlet manifold

The above is part of a Racing Puma inlet manifold. It is broken, resulting in my iva fail. These manifolds are scarcer than hens teeth. Any advice on the best way to weld it would be appreciated?

Deep v and TIG weld would sort it.

Should cost peanuts

Want to bring it across to Dunfermline and I can try Tigging it.
Douglas.

It's aluminium isn't it ? It should tig with 4043 rod simply enough, nothing fancy about it.

[Edited on 26/6/13 by Peteff]

Just to point out that this will be cheap grainy bastardised cast ali not pure solid ali, when you hit it with the TIG arc the crap in it will blow out the same as trying to weld galv.

Yep looking at the granular nature of the casting i have to agree. I think that will be a bit more difficult than it looks at first glance. You may have more luck using some durafix rods or similar rather than tig. Good luck either way hope you get it fixed

It might be an idea to just hit it with the torch and boil the impurities out first, then grind it clean and fill the gap with rod. It does mean you'll need to make a jig though as obviously misalignment could be an issue.

Super glue!

Decision (and thanks to all who contributed to this thread)
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I have not done enough cast alloy welding to entrust myself with a part costing me £700 s/h (purchased over a year ago and fitted by the engine tuners). However the last time I welded a casting of that sort I used a spool on Mig and grew a new part of the casting as the bit causing the hole was missing. It was however totally successful but was owned by someone else!!!

Plan A
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I have entrusted it to a friend who has more experience than me with alloy cast welding, he is currently cleaning the casting in an ultrasonic bath most of today. He is then going to jig the part tack the break it at either end then V cut the crack on both sides. The hole job will be heated very hot before any welding.

I am not even going to look at what he is doing while he is doing it. When finished he is going to rough grind it when finished and leave the final finish to myself. I can face it up on the milling machine when finished as necessary.

Plan B
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Grow a new lug as above if plan A fails!

it will tig up. i have done loads of cast ali and its much easier to do than cast iron