How to Weld Repair - Cast Aluminium intake manifold

Cast aluminium weld repair on this Honda RBC intake manifold.

[@weingump2602]

Used manifold $100, welding job: $200

[@Smffab]

This manifold cost me £100 and they are worth £350. Welding job was free to me as this manifold is going on my own car.

[@Smffab]

Would you say about $200 for a repair like this?

[@arsalan101]

How much would you charge for a customer?

[@nobiden3134]

​@arsalan101 being that you could pay $2,000 for a port job.. that could easily be $500 with a blend and resurface.

[@1nvisible1]

*We'd get $350 min for that but we'd mill the mating surface flat after we opened up the ports.*

[@johnjohnt1989]

Not gunna lie, the end result was better than new. Hats off!!

[@Smffab]

Thanks 🙏

[@m.haslam8495]

It's always brilliant when you see a professional working. This guy is an artist. Well done. Simply awesome. 🇬🇧

[@Smffab]

Thanks mate, appreciate it.

[@danielreyes-dj4nq]

You just got grounds inside manifold its ruined ...great job genius

[@Smffab]

Yep totally ruined. I didn’t even wash it and blow it out before fitting either, so my engine is ruined too.

[@henkkoning2250]

I think it is awesome that someone decides to fix it, instead of just chucking it in the bin. With a lot of expertise to boot.

[@Smffab]

Thanks. Saved me a few quid as these are not cheap to buy.

[@ACommenterOnYouTube]

The issue is finding someone that KNOWS how to do this in your city or have to ship it out states away

[@bazzingabomb]

Great work better than new, it's really enjoyable watching somebody at the top of their game doing work like this. These skills are dying out.

[@Smffab]

thanks, thats very kind.

[@tireballastserviceofflorid7771]

I used to run a mobile welding shop in the carribbean for 11 years. Had a call one day to water island. Had to take a people ferry over and walk tue equipment to the job. The lady had a cracked engine block on a little suv. The bolt bosses were ripped off. I didn't have a portable AC tig just DC tig. I offered aluminum welding rods but refused to back the work. I promised to do my best but assured her it probably wouldn't work. I ordered in a huge box of rods and welded the block up. The ground with a 4inch grinder and made it mostly flat on the 3 pads. Drilled amd tapped, but only with 5/16 grade 8 bolts as per the client. That car lasted another 6 years without issues. I still don't know how it held. She paid me well and fed me. Said it was cheaper than a replacement by far. Happy customer happy life..

[@Smffab]

Nice job 👍🏼

[@Athiril]

Thats great, and they have lower peak pressures/temps vs performance/modified vehicles so they can get away with a lot more. Just means you did really solid work.

[@ghengriff3600]

I’m not an experienced welder but I must say, the way in which you grind out all the voids is the same technique as when welding high pressure pipe. Your attention to detail is inspiringly impressive.

[@Smffab]

Thanks, appreciate that. Wanted to ensure it was as strong as possible. It’s going on my 450bhp AWD Honda Civic.

[@tectrek8]

five minutes and 22 seconds well spent on this incredible video!!!

[@Smffab]

Thanks very much, glad you liked the video.

[@negritorican]

This is craftmanship art at its finest. This guy is worth every penny.

[@Smffab]

Thank you, very kind of you.

[@pumm3l46]

Great video! once you started grinding the broken piece and manifold I was thinking to myself how are they going to make sure the bolt hole is in the right place?? Then you bolted it down before welding to make sure it's in correct placement. I also liked how you used the gasket to ensure the port was sized correctly, Good thinking!

[@Smffab]

Thank you! I keep a scrap cylinder head for for things like this and mocking up turbo manifolds too 👍🏼

[@st939]

The difference between a professional and the others....fantastic job!

[@Smffab]

Thanks, much appreciated. 👍🏼

[@ListlessSpectre]

Once I saw the ports getting feathered in, I knew it was going to be a job well done.

[@Smffab]

Thanks

[@split150]

Wow, that turned out great. Tons of ways that one could have gone south in a hurry.

[@Smffab]

Thanks. 🙏

[@mikethespike7579]

I've never welded aluminium so I haven't a clue, but that looked like a lot of material taken off for the weld bead. Great job, looks like new.

[@Smffab]

Yes youre right a little bit more than I would have liked but it’s not a problem. I could have used a smaller carbide burr tool but didn’t have one. Thanks.

[@johnniethepom7545]

That reminds me , I need a check up at the dentist 😫 .

[@Smffab]

😂😂😂

[@b0bden]

Thank you for repairing this manifold, great job, keep it up

[@Smffab]

Anytime

[@nickmacdx]

I came here in equal measure to admire the artestry and to enjoy the Einsteinian levels of knowledge in the comments. Both were found to be present 😊

[@Smffab]

Glad you enjoyed it!

[@mondecruel1866]

Top quality repair very professional 👍👍

[@Smffab]

Thanks 🙏

[@rc-fannl7364]

Skillful repair, a joy to watch

[@Smffab]

Glad you liked it

[@the.unhappy.mechanic]

It's a great repair. After that, you should have each runner flow tested and cc'd to make sure each runner matches, or it could cause problems in performance.

[@Smffab]

Thanks. It would be interesting to see what it flows.

[@chriswood9195]

Most people rely on JB weld too much, don't get me wrong though as JB weld is good but for jobs like this no, you are better off taking the time to do it right, great work 👍

[@Smffab]

Yes I certainly think so too, thanks

[@Pablomaniac]

Looks great, nicely done 👍🏻

[@Smffab]

Thanks

[@memybikeni9931]

2:47 now there’s a good example of carefully using tools in an expert hand to achieve great results.A linisher making good a mating surface. May not replace a fly cutter, but would definitely clean up a surface.

[@Smffab]

Thanks man! Appreciate it. Would be nice to have a milling machine in the shop. The linisher is good enough for now.

[@memybikeni9931]

@@Smffab Yes I never thought of it. I have a belt sander I can use for smaller jobs.

[@YODAMAN5]

AWESOME job. I need to bring my transfercase support to you to fix...lol MOPAR 4 EVER.

[@billhigdon9104]

that is some fine repair work.

[@Smffab]

Thank you

[@deebee3901]

Lovely repair! Well done mate!

[@Smffab]

Thanks 🙏

[@josearos]

Nice Job, greetings from South America, Santiago de Chile.

[@Smffab]

Hi 👋 and welcome to the channel, thanks.

[@JLange642]

AWESOME damn work you do!

[@Smffab]

Thanks, appreciate it.

[@granite676]

Goood job ! 👍😉 from a fellow fab/ welder 👍

[@Smffab]

Thanks 👍

[@Falco45able]

Good job , those R tech welders are awesome I have the 170 digital, stay lucky, stay safe!😉

[@Smffab]

Thanks mate. They are great value for money, I’ve never had a problem with mine, and I’ve managed to do all kinds of jobs.

[@vinnygoombatts1458]

Wow that's amazing,,,,,,,outstanding work

[@Smffab]

Many thanks

[@ntal5859]

In the 1970s this man would have been a dentist.

[@Smffab]

Haha I’ll take that as a good thing

[@andyramos9542]

You are very skilled! 👌

[@Smffab]

I try, thanks

[@ajpspecialistcars]

Excellent work

[@Smffab]

Many thanks

[@bob.s795]

Sir, you are an Artist. very nice work.

[@Smffab]

Thank you very much!

[@killsammy_]

Hello, it's exceptionally good.

[@Smffab]

Hey, thanks!

[@wernerxldata]

Quite enjoyable to watch this, you've got skilzzz

[@Smffab]

Thanks

[@paulsotheron710]

Nice job. Impressive.👍

[@Smffab]

Thank you 🙏

[@davidnclearlaketx]

Great job! 👍👍😁 Very well done!

[@Smffab]

Thank you very much!

[@MiguelLopez-ow2pc]

Buddy, you are THE BEST! WOW! 😲👍🏼

[@Smffab]

You are the best

[@speedglider2536]

nice professional job 👍

[@Smffab]

Thanks 👍

[@marioobermaier6911]

Respect great Work !!!

[@Smffab]

Thank you 🙌

[@philtucker1224]

Heating the whole piece in an oven is preferable rather just heating the localised area. Also avoid using a sanding belt linisher to re flatten a skimmed face if possible as they tend to shave a lot more off each end than in the centre and you may end up with a poorly sealing face. (Best re-skim if you can afford it).

[@Smffab]

Thanks

[@Spiritof_76]

How fast does aluminum cool down once out of the oven? Was the surface flat and did it appear to be functional?

[@BoneCrusherofOlde]

Beautiful, restored and enhanced

[@Smffab]

Thank you very much!

[@enesfazlic6017]

Great video thank you.

[@Smffab]

Glad you liked it!

[@buffsheeri]

Wow well done, excellent work.

[@Smffab]

Thank you very much!

[@user-ot6qe4yh2o]

Great work !!!!!!!!!!!

[@Smffab]

Thanks a lot!

[@jimwaters304]

Real nice work.

[@Smffab]

Much appreciated

[@arneminderman3770]

Great job!!

[@Smffab]

Thanks!

[@bobwhite4344]

very nice job.

[@Smffab]

Thank you

[@cliveblacksheep2522]

Very nice work ❤

[@Smffab]

Thanks ✌️

[@amgc637]

10 out off 10 repair!

[@Smffab]

Thank you

[@grahamcole4240]

Great job.

[@Smffab]

Thanks!

[@kabelapa]

Did you feel any power increase on opening the runners?

[@Jimboslice911]

I have repaired a couple of manifolds with JB weld... lol

[@Smffab]

I’ve never used it but fair enough if it worked

[@peterfowler8044]

@@Smffab As much as I like JB weld , it certainly wouldn't have anywhere this much strength , very nice job :) .

[@Smffab]

Thanks 🙏. This intake manifold is now installed on my AWD Honda civic turbo.

[@jwalster9412]

I can't imagine those lasted more than 5 engine cycles.

[@errolpoxleitner9586]

Good job.

[@nickaxe771]

Very nice job Sir.

[@Smffab]

Thank you

[@Jaylikescar]

This is why some of us use jb weld lol 😆

[@davebrookbank4831]

nice job.

[@Smffab]

Thanks!

[@hahoblabla2749]

Nice Job👍🏻

[@Smffab]

Thanks! 👍

[@user-dl6ow2oi1t]

당신같은 사람과 일하고 싶다 .. 정말 훌륭하다 ㅎㅎㅎ

[@Smffab]

Thank you

[@gonzalolopez7199]

excelente trabajo saludos

[@Smffab]

Thanks

[@mediumdeli-squishis]

Slick stuff.

[@Smffab]

Thanks 🙏

[@gioglovanroberto1023]

artist, craftsmen

[@Smffab]

Thanks, that’s kind of you

[@patrickzadd5215]

Beautiful

[@Smffab]

Thanks 🙏

[@rizwanrafeek3811]

It is as good as new.

[@Smffab]

Thanks, it should do the trick

[@joon-hn9dr]

it's great work!!

[@Smffab]

Glad you think so!

[@antonmessi491]

Beautiful 👍👍👍

[@Smffab]

Thank you so much

[@CreativeWaleed]

Wonderful

[@Smffab]

Thank you

[@SLK638]

Good job...

[@Smffab]

Thanks 🙏

[@waltz608]

Great job

[@Smffab]

Thanks 🙏

[@Omardottcom]

That was cool

[@Smffab]

Thanks

[@Gary_in_NoVA]

Beautiful TIG work; you are a true artist. I just wonder if the cost, in terms of your labor, was worth not just replacing it with a used, reman, or even new manifold.

[@Smffab]

Thanks. Definitely worth fixing in my opinion.

[@shanehumphrey4827]

Easily. That is a clean casting internally!!!

[@Smffab]

It was cleaner than I thought it would be

[@shanehumphrey4827]

@@Smffab ya it was. I could see it!!! So you know i know my shit. !! Good job. Give you a tip. I used wd 40 and very course metal rotary file bit. To hog repairs out. Stop WD40 a bit before finished (dont use excessive). Then dry to complete!! The aluminum flys out as it dont stick to cutter !! Water might even work!! Just needs lube of some sort. But I probably would have just built that part off broken with weld. And ground, filed,drilled it to factory. Ahhh up to the guy doing it always. Right on bro

[@philippe3430]

Very nice job ! What brand of milling cutter do you use for aluminum ?

[@Smffab]

I’m not sure on the brand, I found it on eBay. Just search for carbide burr for aluminium

[@philippe3430]

@@Smffab OK, thanks !

[@Troy_Built]

As a final step on restorations where the repair must be undetectable I've seen an engraver used to replicate texture.

[@Smffab]

Yeah would have been ideal! I just don’t have an engraver unfortunately

[@alanrichardson7244]

Excellent craftsmanship. You really know what you’re doing. Is the weld against the two parts as strong as the cast part?

[@Smffab]

Thanks, I’m just self taught and a lot of it from KZbin videos. Yes it’s probably stronger.

[@anthonylove6639]

Rooking Reary good boss!! 😅

[@Smffab]

Thanks 😅

[@PaulMay1508]

Hi man good job I don't know alu. You pass the blowtorch to warm the spot before welding or to remove water condensation or for else reason ?

[@Smffab]

Hi, thanks. To be honest the blow torch not really necessary, but because my machine is only 160 amps it helped warm up the part. So just as you say it helps warm up the spot I’m welding and remove the moisture. 👍🏼

[@brenthodges7202]

I miss doing stuff like this. Now I just order a new one because people don't want to pay for it and I don't have to time any more :(

[@Smffab]

Yeah I know what you mean. This was for my personal car and I bought it with a throttle body for a good price.

[@dalegibler602]

So true. People don't understand the talent it takes to do this or the cost to buy quality equipment

[@rascalwind]

Oooo. An artist

[@Smffab]

Thanks

[@holidayrap]

Why is preheating necessary before the welding job?

[@Smffab]

It wasn’t really absolutely necessary, but because I have lower powered machine (max 160amps) it helped me get going with the initial weld, rather than waiting for the welder to do all the heating up before starting to add filler

[@dogyerf21]

I seen this father son mechanic down here the road from me other year everyday they would pick apples on the side of the road. I would always wonder what they done with a them apples that they were picking every day. So I seened them at the mechanic store and asked em.

[@Smffab]

😂 interesting…

[@michaelszczys8316]

Welding it with a nice TIG welder and even able to bolt it onto the things it bolts to. Man, thats way too easy. How can you miss?

[@Smffab]

Super easy!

[@trezvyisvarchik]

Аплодирую стоя 👏

[@Smffab]

Thank you!

[@keithmulhern3148]

Honda would have run for ever with a broke intake lol nice work

[@Smffab]

Haha no doubt, thanks.

[@telosfd]

Super! That was a TIG welding?

[@Smffab]

Yes it was!

[@harrygatto]

Great job. How long did it take in real time, start to finish?

[@Smffab]

Good question, probably about a couple of hrs.

[@harrygatto]

@@Smffab Thanks, that's good going.

[@anonimous336]

Can you show us how to do a cast steel exhaust manifold repair?

[@Smffab]

if one comes up i certainly film it

[@patriciafettuccine7324]

As long as it works👌

[@Smffab]

It fits and works 👍🏼

[@TheeAthis]

Did you use Helium or Argon?

[@Smffab]

I used argon for this.

[@buzzedalldrink9131]

you could have used the aluminum rods they sell at the flea market. If they can stuck two soda cans together with a propane torch, they should work just fine here😂😂😂😂😂😂

[@Smffab]

😂😂

[@buzzedalldrink9131]

@@Smffab I was too busy trying to be funny and forgot to say, Awesome job! I wish I could weld like that!

[@Smffab]

Thanks! I’m self taught from KZbin, so anyone can do it if they want to.

[@buzzedalldrink9131]

@@Smffab thats good to know. I am also self taught, getting into mig is my next step. thanks for the video!

[@ianholmen888]

What kind of grinder bits are those?

[@Smffab]

Carbide burr specifically for aluminium

[@onetun6953]

Single cut

[@jirkarutar1052]

Kompliment ❤❤

[@Smffab]

Thank you 👍🏼

[@pauljanssen7594]

Yepper go to one of them U-Pull-It junk yards it's a lot better and cheaper.

[@Smffab]

👍🏼

[@H33t3Speaks]

Propane torch, Alumiweld. It’s a 4-banger honda, save the time for stuff that matters. Solid work but that mating surface should be polished up.

[@Smffab]

Mating surface is fine. Saved £250 on this intake be repairing it

[@Spiritof_76]

Polished up? For a gasket?

[@YURYLYAKUSHEV]

🔥

[@Smffab]

Thanks

[@milolll]

Expert pray tell: cast aluminaium ok to weld, but cast iron not ok?

[@Smffab]

Both can be welded.

[@user-ce2yc4no1f]

4043 filler? High silicon, bright finish, looks wet, need that "flow".

[@Smffab]

Yes that’s right, 4043 for castings

[@user-ce2yc4no1f]

@@Smffab Thank you! I was trained as a welding engineer at OSU in the 80's. I still remember, and live metallurgy. 5053 for marine, 1100 for Pure, and there are a few more.

[@marktzu5117]

Get one at the car junk lot 😅

[@Smffab]

Not one of these, they are worth about £350

[@Athiril]

I thought he was about to reuse the aluminium shavings

[@Smffab]

😂