HEAD REPAIR ( HOW TO WELD CAST IRON )

Prepping and welding the cracked head on the Stover hit and miss engine.
Check out 500passwords / 500passwords

[@montero0987]

this is what i love most in youtube,,watching you guys share all those tips which will take me years ( and a lot of money in wasted materials) to get it right..more power to you guys.

[@805ROADKING]

Thanks alot Bud!! We appreciate you watching!!☺

[@roymartin4771]

used to weld liner plates in crusher box for a scrap yard. they used an old refrigerator with only the light bulb inside working to keep rods dry. worked very well.

[@captain757747]

great video. My dad used to have a shop and did major overhauls. The ford 390 heads used to be a big problem with fractures. We try to tell people when they start their car in the morning ( usually 0 degrees or lower out side temp) let the car idle for 3 or 4 min to prevent thermal shock to the exhaust side of the head. this is where the cracks usually develop. We would put the head in a kiln made for ceramic and slowly raise the temp to a cherry red and then weld the head immediately after welding ,the head would go back into the kiln and we would slowly lower the temp to prevent warping. I hope people watching your video pay attention as this is an art in itself an those that think they know it all will find they did not know as much as they thought after watching your video. Hats off to you for sharing your video and demonstration of true craftsman skills.

[@805ROADKING]

+captain757747 Thanks Capt!! Yeah the welding part is easy, the heatin' and cooling down part is critical!!☺

[@bradwentzel]

I had a cast iron head crack on an old 1988 Dodge Truck. I literally looked like Uncle Bucks car with the steam coming out of the exhaust. I removed and took both heads to a machine shop that heated them up in an oven that he made from stacked bricks and torch to preheat the metal. He then welded heads and pressure tested to assure he fixed all the leaks. He then allowed the heads to slowly cool to room temperature. He then machined the heads and installed separate seat inserts. The machinist made a comment that he has never had a cast iron head crack again after welding it with his process. Here is a behind the scenes look into what happened. Prior to unleaded gas, lead was use to protect the valve seats. After the switch to unleaded gas, the auto manufacturers had to start using hardened seats. There are two ways to get hardened valves seats. One was to machine the heads and install hardened valve seats into the head. The other way was to super heat the cast iron head and cooling it quickly by quenching it with water. This rapid cooling hardened the cast iron and was a cheap way to make hardened seats. The downside of this method is that the harder metal was more susceptible to cracking. That is why so many vehicles had heads cracking in the 80's. The machinist without knowing it was changing the cast iron back to the way it used to be and his separate valve seat inserts is the way that heavy duty heads are made. His fix wasn't a band-aid. It created something better than the original.

[@mauserhouser]

used to watch an old man in Bakersfield weld oilfield pumping unit engine heads that were cracked. he'd sit them on a wood burning stove and stoke the fire pretty good and let them sit there for an hour or 2 and then weld them and then stoke the fire again and go home and let them cool down gradually as the wood burned down and the stove cooled down to ambient temp. he'd always peen the weld Peening is one way to counteract the shrinkage forces of a weld bead as it cools. Essentially, peening the bead stretches it and makes it thinner, thus relieving (by plastic deformation) the stresses induced by contraction as the metal cools.

[@davidmethvin1705]

Mauser Houser I said the same thing before I read your comment

[@darylm3850]

I knew a Jack Zerkle from Bakersfield who did the same.

[@oldchevy4x4]

Welding cast iron can be troublesome for sure. Parts need to be clean as the driven snow, pre-heated & very slowly cooled. I've had good luck using 1/8" Nomacast rod, and cooling parts in sand or wrapping them heavily in welder's blankets. Looks like you 2 did a fine job! How cool is this "community" here? 500 & his parents just jumped right in... they (like a lot of the folks here) really are good people!

[@brianb5779]

Your video helped me remember stuff i was taught and forgot so thank you very much!! Like the one guy said, so much of these skills are being lost and forgotten so thats why i love youtube and guys with great knowledge like this can share for those like me who want to learn, so thank you.

[@805ROADKING]

+Brian B Thanks alot Bud!! We appreciate you watching!!☺

[@junkman6261]

Just wanted to say thanks for posting this video! It's hard enough to find a professional in some places that can weld cast iron, especially where I live. Nice work!

[@RamblinAround]

It was really cool to see the process...I've always wondered how to weld cast iron. Interesting vid...nicely done!

[@Lumpyone]

I learned to stick weld in the early 70s, and it was 'preheat and use the right stick' with cast iron. That and real brazing, it was actually fun. Used the skills for a long time.

[@Tubecraft1]

excellent video and a huge thankyou for the tips you enabled me to successfully weld a broken rocker arm. I thoroughly degreased it overnite in petrol changed the petrol 4 times in a mug and pre heated it as you said and used nickel rod and it flowed beautifully and looked very good THANKS to YOU guys

[@805ROADKING]

Thanks Bud!! I appreciate you checkin' it out!!☺

[@GarrettJDB]

500 Is a great guy. Thats quite the process of welding cast iron. Good job.

[@805ROADKING]

Thanks for checking it out Bud!! I don't know about MIG, but I'm sure you would need nickle wire or a wire specially made for cast!!☺

[@805ROADKING]

@KrankieV2 Thanks Tom!! We'll have to wait till Spring to paint it and reassemble it!! Thanks again for watchin' Buddy!!☺

[@strattuner]

you have to use the certanium, and this guy did it perfect,no matter what,no matter how good you do it,if it is a piece that has to hold water or chemical you have to machine it flat,one more little tidbit,after welding let it come back to same temp as heater,then throw it in lime,till it goes to ambient temp-70-100 not cold,if you are in a hurry let somene else do it,this is not a job for a hurry up harold,patience is the key

[@805ROADKING]

Thanks Strat!! Well said!! Most people never seen the video after this one where the weld was ground down to make there repair invisible!!☺

[@Micscience]

Well the only point of maching it is to insure the head is in spec right? So you don't really have to machine it if you measure it and it is within spec.

[@domingojoseph1396]

strattuner nice to see

[@805ROADKING]

@not2fast4u2c Thanks Jim!! Yeah I was quite impressed with that rod myself!! Thanks for checkin' it out!!☺

[@happykat39]

The Certanium rod is a necessity for large welding projects but Airco 375 is cheaper and works just as well for smaller items . Also, I learned that along with proper fixturing higher heat than you used is required if the part has to be re-machined through the weld line. I use an acetylene torch to bring the piece to a dull cherry red in a dim room before starting to weld. Then you can machine the piece with conventional tooling without running into hard spots at the weld/iron interface.

[@karolthiesen4707]

that's wild that you stick welded that. great technique about the preheat and cooling. I'm going to have to remember this if I get a chance to use my powerarc welder this way. thanks for the vid.

[@ShawnCFarm]

It looks really good. I think you got it and it should last a long time. 500's the best. Just wish all you guys lived closer

[@ernienapier70]

Great tips. I've got to remember this if I ever run across a job for my powerarc on cast iron.

[@timothycor123]

Great work guys very impressive never saw a cast iron head fixed

[@805ROADKING]

Tom bailed on KZbin since that video was made!! Thanks for checking out the video!!☺

[@tacky7719]

@805ROADKING Thak you for your prompt reply! Nickel wire is very good to prevent brittle weld metal. But so expensive!

[@garywestin6907]

Pretty cool technique. I think a lot of viewers would have TIG welded it. I showed this video to a friend of mine who just bought an Everlast TIG welder and he said that TIG welding would have been the way he would have gone.

[@stevothegreat64]

I used to do heat treating and preheating for piping in chemical plants and oil refineries in Houston. Made plenty of furnaces and preheated plenty of pipe, never used a BBQ pit though. Looks like it works good. Not doggin you but I did laugh a little when I saw the pit, but nice improvising.

[@michaeldvorak5556]

I've seen it before were someone used a gas grill to pre-heat the cast iron. Size of part may not allow this. But after welding then they put in sand and completely covered with more sand to slow the cooling. Any part that isn't covered will cool at a faster rate and cracking likely.

[@strattuner]

MCSCIENCE,YOU are right ,if the piece hasn't warped out of spec,that my friend rarely happens, you heat the piece to keep the part at same temp,temperature shock,means defect,seems every part I ever had to weld or repair by welding required touchup,even if it was just a file LOL,patience is the key

[@AntiqueWindmills]

Hitting it with the point of your welding hammer throughout the weld process will relieve the stress in the weld and it's less apt to give you those hairline cracks as it cools. Keep up the good work !

[@805ROADKING]

@RamblinAround Thanks for checkin' it out and commenting again Buddy!!☺

[@Johanreistad]

I loved the video and as I can confirm U did all by the book . When I do this kind of repairs . I normally use a 100 % Nickel rod and wire feeder and pure argon . How ever if U want to use hand held electrodes use pure Ni for the firs layers and try to oscillate so that U blend the new material with the old surface .

[@Goregoonswasteofspace]

Ever get a feeling of Déjà vu? Once again, a fine job my friend!

[@tontobb8956]

We use sand and also use those asbestos fibreglass type burn blankets to cover the job. T slow the cooling right down

[@CumminsDslPwr]

I know I am a bit late to the party, but, I have welded cast many times with good results using Castaloy rods. Most welding supply chains have them, and they are not real expensive. Any high nickel alloy rod will do in a pinch. The prep and pre-heating is the key, which you obviously have down pat.

[@bobbuilder8707]

Wow, nice video. I though you were going to tig weld that head. I just picked up an everlast welder and was thinking about what it would take to weld up cast iron. Great tips.

[@jaysmetalart]

I like to TIG weld cast , no grind, no slag , just a better cleaner weld all around......knock all that flux off that rod and use it as TIG rod....it works so slick.....I never stick weld cast after I had learned this.......Jay

[@Johanreistad]

Never let the piece go below 300 deg Celsius during work and pack her in rock wool when finished . Fore best quality re heat the whole item after cooling and let her cool down in rock wool again before machining . All the best Johan

[@805ROADKING]

Thanks for checkin' it out Buddy!!☺

[@Krankie_V]

very nice work, can't wait to see that engine head in service again. 500 is a great guy and obviously very helpful! thank you for providing another entertaining KZbin video! ☺

[@MrSuperMation]

Great video. Thanks for teaching me something I didn't know.

[@NomaDairy]

Great Work! good ol 500 and family set you up nicely!

[@steamer123]

Nice job you guys!!!! When I need some cast iron welded I know were to go. Thanks for the video.

[@greggfla]

Hey that's really cool that he sent you them rods!

[@805ROADKING]

@oldchevy4x4 Cast can be tricky, that's a great idea with the blankets!! You're right alotta great folks on the Tube!!☺

[@user-tr4op2fm7v]

cast steel is weldable. Most cast iron has to much carbon and sand to weld. I use Nickle rod and preheat then anneal in oven . Very tricky on parts that experience heat cycle . Hope you fix it. Nice channel thanks for sharing cool old motors.

[@805ROADKING]

@happykat39 Thanks for the info Kat!! The Certanium rod was given to me, but when I run out I will give that 375 a try. I don't do any big jobs!!☺

[@805ROADKING]

@buster4236 Thanks Bud!! You raise a good point!! We'll definitely be doing things a little different next time!!☺

[@805ROADKING]

Thanks for checkin' it out Bud!!☺

[@GatheringSticks]

very informative and useful video...hats off to 500 too.

[@805ROADKING]

@GatheringSticks Thanks Sticks!!

[@805ROADKING]

@ColtDeltaElite10mm Thanks Bud!! The amps might have been a little higher, the indicater on that machine isn't accurate at all. I think the rod company recommended 65-70 amps!!☺

[@805ROADKING]

@BrainEatingZomb1e The migs can handle 95% of your welding needs, but the Arc welder is handy and they're pretty cheap!!☺

[@805ROADKING]

Thanks alot Bud!! I'm glad it worked out for you!!☺

[@rovid1000]

you're ultraviolet rays destroyed my monitorr ...ha

[@grantw.whitwam9948]

Beautiful grinding job. I have that exact same gas grill!

[@805ROADKING]

Thanks Grant!!☺

[@motocross03087]

Great video and nice narration, thanks for the video.

[@805ROADKING]

That sounds like a good system!! It's amazing what you can do with a die grinder and a 4 inch angle grinder eh!!☺

[@brandonquenneville7330]

this guy is very smart and a fun talker

[@805ROADKING]

@oldtime40s Thanks Buddy!! those engines will be around long after we're gone!!☺

[@805ROADKING]

@carnivore10 Thanks Tom!! Good luck with the computer!! I'm running outta space on mine now, gonna have to get Lil Racer to Ram it up!!☺

[@805ROADKING]

@motocross03087 Thanks Buddy!! I appreciate you checkin' it out!!☺

[@805ROADKING]

@MagicCadillac thanks for checkin' it out again Buddy!!☺

[@Johanreistad]

When the groove is cowered with pure Ni u can go lower in quality of sub material to save some money . Always chip the surface between layers and best is to use air hammer . For instance Atlas Copco rrc 12 or 13 witch haw sufficient impact to float the material . Do not use a high frequency hammer as she will only remove the slag and not the tensions.

[@805ROADKING]

@Goregoon Lol!! Déjà vu all over again!! Thanks for checkin' it out again!!☺

[@user-tr4op2fm7v]

Cronatron brand rod works well Nickel rod. Welds cast steel great.

[@kenoaka]

The reason the whole chunk came off is your heating it in one place. Cast iron can't be heated in one spot, if you really want to know how to weld it, you must place the whole head into a bed of red hot coals (wood stove) when it turns red be ready to go and weld it hot, then it will weld like steel. (try it :)

[@cameronsmeaton3812]

you can use tig and for a filler wire use the stick rod and bust off all the flux its another good option

[@MikeMayeran]

Y'all did a great job.

[@805ROADKING]

That was DC!! Sometime you have to reverse polarity depending on the rod!!☺

[@805ROADKING]

Thanks for the info Johan!! I'm sure it will help alotta guys out!!☺

[@805ROADKING]

@cristiandj17 Thanks for checkin' it out Bud!! Cast is always tough, I hope it works for you!!☺

[@buster4236]

These gentlemen have a very informative video in repairing a Cast Iron head with a pretty severe crack. However, you gentlemen might want to move the head away from this "Propane" powered grill that you used to heat the head to 500 degrees. One unfortunate spark landing in the wrong spot could end your day in this lovely shop when the propane tank explodes. Just a suggestion to a fine video.

[@805ROADKING]

I doubt you would get any distortion but it will probably crack, especially without nickel rod!!☺

[@805ROADKING]

@nstahlable Lol!! Thanks for checkin' it out Buddy!!☺

[@spillymon]

I have an exhaust manifold that someone thought the same thing. The mig weld is cracked all the way around the runner!

[@motoforlyfe]

Great video...grandpa5100 said you should have brazed it!!

[@805ROADKING]

Thanks Bud!!☺

[@kenoaka]

The reason it works is because the head expands and contracts equally, also the reason why the piece cracked off when you heated it.

[@stretch561]

Nice job. I always just heat with torch then cool in sand if piece is small enough

[@805ROADKING]

@TheFred1952 That's good to know, I have a TSC right near me too!!☺

[@805ROADKING]

@timothycor123 Thanks Tim!! Hopefully the info will come in handy some day!!☺

[@GnosisMan50]

I was thinking the same thing... I suspect it must be harder to control the bead on cast iron oppose to steel.

[@805ROADKING]

@Serostern Sorry Bud!! I'll have a talk with the Editing Dept.!!☺

[@805ROADKING]

@larrythelookout Thank You Mate!!☺

[@805ROADKING]

Yeah it was for a 1936 Stover 2 HP hit and miss!!☺

[@805ROADKING]

@500passwords Thanks Buddy, they worked out great!! Yeah, but Mom and Dad are Cool!!☺

[@DynoDon7]

have you ever tried mig welding cast iron. I have done a lot of exhaust manifolds and some heads on old engines and never had any crack warp and is a lot quicker than heating and fiddling about

[@805ROADKING]

Yeah we're good friends, been friends since the lean years!!☺

[@805ROADKING]

@NomaDairy thanks Matt!! yeah the 500's are great people!!☺

[@805ROADKING]

@josderedneck22 Thanks Jos!! That is a nice Slaghammer, I don't even know where I got it!! I think it might have came with one of my welders!!☺

[@805ROADKING]

@vidman008 thanks Buddy!! The Tube is full of good people, Including you!!☺

[@805ROADKING]

@outdoorsman310 No that stuff won't work for you!! I'ts just for steel!! What you need is a Pro to weld that for ya, I wouldn't mess with a front end myself!!☺

[@JesseWright68]

I've got that same grill! Cooked some bacon on it just this morning.

[@MrMEmEmEmEMEMEeeeeee]

Very nice video, thanks. I was concerned about the plastic gas can sitting by the motorcycle, though-a few gas fumes creeping along the floor over to the BBQ and POOF!...

[@805ROADKING]

Yeah Buddy!! Thanks alot Joe!!☺

[@krupter]

Nice work

[@805ROADKING]

@junkman6261 Thanks Daniel!! I appreciate you watching!!☺

[@hootinouts]

Good job. Your accent sounds like you're from either the greater Philadelphia area or Southern New Jersey where I've lived most of my life.

[@805ROADKING]

Thanks Bud!! SJ!!☺

[@CHixon]

Good Job!

[@805ROADKING]

@steamer123 Thanks Tom!! Bring it over Buddy, we specialize in Hit and Miss Cast!!☺