Aluminium inlet manifold welding

ChrisJC · Post by **ChrisJC** » Mon Mar 01, 2010 10:54 am

I need to get some welding done on my Thor inlet manifold.

Can anybody recommend a decent ali welder in Cambs / Northants / Beds / Herts sort of area?

It will be pretty fiddly, so somebody good at doing delicate work a bonus.

Thanks,

Chris.

Flying Spanner · Post by **Flying Spanner** » Mon Mar 01, 2010 8:23 pm

Ring The Welding Institute in Great Abington,Cambridge 01223 899000 and ask to speak to Welding Instructors in the Training School.

They should be able to put you in touch with someone on there books whose close to you.

Next question is it an Aluminium or Magnesium casting??

Phil.
Ex CAA TIG Welder.

mgbv8 · Post by **mgbv8** » Mon Mar 01, 2010 9:49 pm

You might want to try this Chris??

I just bought a kit for about £20.00
Chyeck out the other vids on the page.

Eliot · Post by **Eliot** » Tue Mar 02, 2010 12:15 am

post a picture of what you need doing. I can tig ally if i can get the torch in.

kiwicar · Post by **kiwicar** » Tue Mar 02, 2010 7:37 pm

"post a picture of what you need doing. I can tig ally if i can get the torch in."
Highly recommend did a very nice job for me on my manifold last weekend.
Many thanks again Eliot

Best regards
Mike

mgbv8 · Post by **mgbv8** » Tue Mar 02, 2010 8:01 pm

Thats good to know Eliot

I did my C&G mig and tig 33 years ago. And havent touched a tig since.

Eliot · Post by **Eliot** » Wed Mar 03, 2010 8:27 am

Pulls 18Kw when welding, which is 75Amps AC

Here's the graph from sat:
http://www.mez.co.uk/energy/180amp-tig.jpg

ChrisJC · Post by **ChrisJC** » Thu Mar 04, 2010 8:53 am

Sorry, was in Bordeaux yesterday.

OK, I will get some pics soon. Currently it is at an ali-welders, but last time I spoke to them they didn't think they could do it (problem getting the welder in there!). So I suggested they just do it and see how they get on. I plan to call them later and see what they've done and repatriate it either way.

If they've failed, I'll take some pics. I hope it's doable as I've drilled some holes in it, and ruined it if not. (mind you, it is a spare).

Watch this space.

Chris.

ChrisJC · Post by **ChrisJC** » Tue Mar 09, 2010 12:20 pm

Right, liberated it from the not-entirely-useful Ali welders.

Here's the plan:
1. Take a Thor manifold and drill some holes

2. Make up some plugs

3. Weld the plugs into place.......

As you can see, it's the welding part that is proving elusive.

I realise it's going to be tricky, and I fully expect to dress it with a die grinder afterwards, but I really need those plugs welded in so I can tap them out for my LPG injectors.

Eliot - can you do it?

Any other comments?

Ta,

Chris.

badger · Post by **badger** » Tue Mar 09, 2010 7:52 pm

Chris, why not simply fit the lpg injectors into the lower part of the manifold, next to the body of the petrol injectors, at 90 degrees to the manifold? Simple, straight-forward and no issue as you are firing a gas into a gas, not a liquid that can wet-out on the manifold walls. You won't achieve any difference in running quality or bhp by going down the route you're taking here.
Oh, and please make sure to note what way the runners of the manifold go - it is absolutely imperative that the "injector-cut" harness for cylinder 1 corresponds to the correct cylinder 1 LPG injector, and this must follow for all injectors or you will knock the vehicle ecu into limp mode as the lambda cannot trim correctly if you cross-wire any cylinders, ultimately requiring a trip to landrover's Testbook and the usage of one of the 16 programming slots in the ecu. reach 16, it's new ecu time!

Eliot · Post by **Eliot** » Tue Mar 09, 2010 10:05 pm

you can't get the torch down there.
Assuming the holes are true and round (they look like it) make some oversize bungs with a top-hat on them. Press them in, cover with ally filler (devcon) and then dress with a die grinder from underneath.

I've seen a telly program where they fitted gas to one of those manifolds by simply drilling and tapping (about 6mm size) - is that the same as what you are trying to do?

what does it look like underneath? - you may be able to get a tack weld in there.

stevieturbo · Post by **stevieturbo** » Wed Mar 10, 2010 9:28 am

You could Lumoweld those into place.

Although some sort of top hat design so they couldnt push through would be better.

Or likely even any form of chemical metal would work too.

gelmonkey · Post by **gelmonkey** » Wed Mar 10, 2010 5:46 pm

Chris
Kiwicar had some epoxy resin and ali filler powder from me a while back and as far as I'm aware he has had good results with what was sent.
Give him a shout and ask his opinion on the stuff and how easy it is to work with.
I can supply same to you if required.
Cheers
Paul

kiwicar · Post by **kiwicar** » Wed Mar 10, 2010 8:12 pm

Hi
It is great stuff, sticks really well, you can mix it up as thick as you want, self levels a treat, works very well with a knife when soft (just gone off), doesn't pull out and sands a treat. It gives a lovely finnish virtually the same colour as cast ally very close to sheet metal very happy with the result.

Best regards
Mike

ChrisJC · Post by **ChrisJC** » Fri Mar 12, 2010 12:09 am

That filler stuff sounds interesting - what's it's name - is that Lumoweld?, or is that something else?

Badger - there isn't room to go adjacent to the normal injectors, I did look at that, and it's completely inaccessible under there. The fuel rail and injectors completely fill the void under the inlet pipes. You are also supposed to get the pipe between injector nozzle and injector valve body as short as poss......
Ta for the heads up on the relationship between LPG injector & petrol injector - I was aware and I think I've sussed it out. The instructions are quite pedantic on that point!

Underneath is even less accessible. Isn't there an ali-welder technique that has a mig-type torch?, if the material was steel I could mig-weld it no problem at all. There must be some 'craft' type ali welding processes.
What about brazing or soldering?, is there anything like that?

Thanks,

Chris.