TFS: VERY Detailed Info About Weld Repairs

[@TheFabricatorSeries]

Check out Weld Metals Online for pre-packaged and prepped practice metal! weldmetalsonline.com/ Tools & Gear We Use and Recommend www.amazon.com/shop/thefabricationseries Learn to TIG Weld in Our Class! thefabricatorseries.com/classes

[@CLDiesel02]

You’re up late!

[@TheFabricatorSeries]

I'll sleep when I'm dead.... or sometime in the next 15 minutes.

[@HTHCLLC]

Just placed my order. Fast, Simple, Paypal. Also added Justin from TFS sent me in the note. Hope it helps

[@rudyjuarez82]

It’s interesting how you didn’t fudge any of the issues along the way by not mentioning them, so you never seem to amaze me with your honesty in every transaction and or event along the way in your business! I’ve been in to your store and experienced your super honest business ethic first hand. It’s really a pleasure and I love your videos. This is the stuff that takes years of welding experience to experience first hand, and you share everything. Really rare in this world of business practices. Thank you from all of us.

[@lukearts2954]

You know what I like about this series? Aside from the technical knowledge, tips and tricks, you also always talk about the trade as a community, and how important it is to take pride in the craft and ensure maximum quality products for the customer... That's unique, because any other craft channel just gives the insight and tricks, perhaps an anecdote about the particular customer of the item in the video, but never about the whole of the trade community or the reputation of all the craftsmen combined.

[@lukearts2954]

I guess what I'm trying to say is that the explanations in the video seem as if they are intended for training of the people that will work in your shop, signing your name on the product and thus carrying or destroying your personal reputation =)

[@c.j.1089]

When I do intake manifolds, I plug all the inlets and fill them with about a cup of acetone and rise them three times to clean out carbon and oils that will work their way into the welds. This is a necessity for repairing older intakes.

[@johnjay5143]

Makes good sense . I was wondering if it wouldn't hurt drilling the ends of the crack like in cast iron repair (I've never TIG welded but am looking pretty seriously at buying a decent entry level machine soon) . We used to do some repairs on iron manifolds and cyl. blocks and if you overlooked magniflux and drilling you would be chasing the crack like a dog at the track . lol

[@Atari8888]

@@johnjay5143 if you're looking at the primeweld 225x send it, its one of the best investments ive ever made, i learned on it, got far better and even started a side gig with it

[@benrosati8788]

@@Atari8888 I second this. It ends up paying for itself in a few jobs if you know what you’re doing, and you can’t beat the warranty

[@andrewwilson8317]

I have made some shot bags from some leather rawhide off cuts and lead shot. They perfect for locating and weighting down awkward jobs without scratching them and they make great hand and arm rests and guides. They very cheap,especially if sand filled and can easily accommodate any shape. Well worth trying out mate, get some made, you will love them!

[@jeffreyturnage360]

I would be interested in seeing how they work, and were I could get a couple. Do you have a video up? Or link?

[@andrewwilson8317]

They were home made as could not find anything just right on the market. The leather was offcuts and a couple of old welding aprons. They can be made to suit whatever leather you can find. I wanted them to be as heavy as possible hence the lead shot. The lead came from a supplier that sells if for filling shotgun shells. Sand would work just as good but not as heavy. It's important to it over fill the bags as they need room to bend and hollow to shape to suit. I only used leather as I figured welders aprons probably the most fire resistant material against sparks or bits but for tig only maybe a heavy duty canvas would do? Will take some pics. Once you try the shot/sand bags you will love them. Any local cobbler or leather worker could knock out a few of different sizes for you? You could have your own signature series of welders shot bags!

[@Eric-Weldabull]

Lol, we don't have OCD, we are just tig welders and it needs to be perfect, that's all...

[@Vieledspy]

Eric Charette couldn’t agree more

[@gregkral4467]

you know it Eric, you know it. It is gonna be perfect...... period. So simple.

[@jaysen2200]

Just perfect pfft uncultured swine it must be better than perfect !

[@jaysen2200]

@@MJ-nd7cj there is totally cable it is incorporated into the gas hose

[@Jimmermahomoney]

Word

[@babyruuth]

Great to see repairs like this, no one does perfect work every time no matter what the internet says. Thanks!!

[@breakawaymotorsports]

Lean intake "pop" probably caused this to baloon and crack. Excellent tips....thank you!!

[@88_turbo_fox73]

I'm new to tig welding and have mig welded on assembly lines and it's so hard, I have a button on the torch that I just can't get away from, I try using the pedal and it's just frustrating bud, everything I kno about tig welding I've learned from these videos, the most detailed I've seen

[@SuperRandykid]

If your machine supports it, get a tig torch without a button, or run with it unplugged off the machine Tough love, forces you to learn and respect using the foot pedal 👌 I always struggled with a pedal until I did this, now it's second nature

[@kinzieconrad105]

Turn your heat up, make multiple passes. Grinder is your friend who rarely gets to play but makes every game. Thick is easy thin is hard two str8 razor’s cutting edge to cutting edge is possible.

[@weenercatotto]

Square corners frequently crack on pressure vessels, temperature and vibration extremes. All present at the races. That square corner should have been at least a 1" radius.

[@SWTWHITEGSR]

A beast at tig welding and instructor !

[@mattnsac]

Get yourself a Magnaflux Dye Penetration kit. Super fast to do a crack inspection and is as easy as spraying on the dye and some developer.

[@therealchayd]

+1 this, I spent ages trying to chase a crack in a transmission bell housing, dye pen kit made the whole thing stand out nicely.

[@NoWay-vz9xw]

I guess I am a rare non-welder as I always appreciate a good weld. Welding is kinda like chess anyone can play, but to play it well is a bitch. Great looking weld by the way.

[@PPAATTful]

Great job, very good dialog you hit all of the important points. I'm a mechanical engineer for 40 years.

[@sacrificialrubber779]

Maybe oil inside working its way out? Degrease the inside of the manifold maybe?🤔🤔😁👍🏻

[@RambozoClown]

For sure. Take off the throttle body and clean and inspect where you are going to weld whenever possible. You never know what you will find if you don't look.

[@gusbisbal9803]

not maybe, it has a throttle body, what do think was being sprayed on the inside. I have no idea why he didn't pour some acetone inside and shake it all about x 5. If he had an employer asking him to do that and he didn't clean the inside there would have been a "what the F@#$%!" moment. I like this guy but he definitely did a good enough is near enough job on this.

[@brandona4618]

Eh. Close enough for government work.

[@dougankrum3328]

Yeah, first thing I'd do is remove anything fastened to that manifold...and get a better look inside...especially something like the throttle body...could be a little heat-sensitive...@@RambozoClown

[@dougankrum3328]

I'm with you on the acetone...pretty cheap compared to a 'come-back/return' from the customer...@@gusbisbal9803

[@mikedmt]

Love the series. Super informative, and well done. Thanks, as always. Maybe there was schmoo on the inside of the tubing that came through the repair. Either way it's fixed, and since it's obviously not a show piece, the uniformity isn't as important as the functionality.

[@martinmaurach6422]

I've mucked up a part or 2 over the years when I didn't directly clamp a ground to the part.....Very thorough vid. thanks

[@Rickybobby702]

I’m super excited to pick this up! Looks amazing great job per usual. And looking forward to future works for sure. ✊🏾✊🏾

[@prelich01]

Nice video on welding repairs w/aluminum. I learned a lot that I have never considered before and a technique to address it.

[@VinceLoschiavo]

Well done! Love the Jimbo's Garage torch holder too!

[@brettmansfield3136]

You might already know but they got angle die grinders (Like a mini angle grinder that doesn't overheat and runs off an air compressor) that have flapper wheels as well as other abrasive attachments for tight areas.

[@pirobot668beta]

My uncle had a process for intricate aluminum parts, like intakes. He would fabricate the piece, taking care to keep the cross-sections uniform, smooth fillets. Then he'd fill the piece with plaster, allow it to set then roast it a bit to drive off moisture. Hey, it's a core! Then he'd weld on some solid sprue plugs, invest the whole thing in more plaster. Roast again to get it all bone dry, then fire it hot and long enough to re-flow the whole thing. His idea was to turn a collection of welded parts into a single sound casting. The sprues were for both over and under flow. About one out of five was a dud.

[@richardsolomon8076]

Thanks for sharing, great tips on costumer service and adjusting your own welds to match. Valuable knowledge :-) thanks again

[@resspls10k]

100% about needing some practice before starting the job itself. I know welders who just pick up the torch and go. I, on the other hand, need to lay down some comparable joints on scrap first to "calibrate" myself to the job and get rid of shakiness in my hands and arms.

[@daviddroescher]

Question Why no stop drills? Is it because of the nature of the specific project that will be replaced in very short order, said that it was only meant to get him on the dyno and to be replaced or reconfigured so the final finish is not so important. You said you did not want to get 100% penetration as the likelihood of a blowout is too high. Lacking 100% penetration the crack still exist in the underlying material. A crack is a crack it will always grow especially in a pressure vessel or high volume of heat cycling both of which this intake will see

[@mikeford963]

I had the same question. I was taught to drill out each end of the crack to terminate it.

[@michaelabraham9177]

I weld primarily with mig. I've noticed any type of closed container, or closed pipe, or anything that prevents overdressed of hot gasses being able to vent will do so at the weld lol. Since argon is heavier than air you could leave a small hole in your tape at the top to allow any gases boiling out of your parent metal to escape might help when you get towards the end of those welds

[@dolphincliffs8864]

Stop welding and let the gasses cool and then finish the weld.

[@WickedMoto]

YO!!!! You're awesome man! Thank you for the information in the video and thank you for the hook up on the weld metals! I have been looking exactly for something like this so I can practice with my new welder i just wired up and got everything for. Just needed the metal it self! Thank you! I appreciate it so much I just placed my order and bought $100 worth! So freaking stoked to get that and get going on practicing!

[@anetworkservice]

Good video! I appreciated the info about Weld Metals Online. I went over and picked up a few kits for me to practice on. Especially for aluminum skills. I've been needing practice materials.

[@rebeljoker9209]

Good video man I just bought a new Tig machine and I'm waiting for in to get in. Your videos are great for catching tips on tig, keep up the good work man

[@Sugiemonster97]

The talking isn't bad his voice is a good voice to listen to

[@donaldroberts6452]

Outstanding video. Sometimes I've learned..some jobs I just wont take anymore.

[@Michael-yp5jw]

Do you ever need a dye penetration test for repairs like this to determine if theres any thin, hard to see cracks through the rest of the weld?

[@AbyssalSardar]

It looks really clean to me, I wouldn't complain about that repair.

[@pknkustmz2948]

I swear i hate welding on intake tubes and intercoolers that have already been used you always get crap floating to the surface but thats how it goes lol i literally just welded a bung on my freinds aluminum intake tube and it started getting floaters half way through the weld.

[@altonb93]

Some of those aftermarket intake tubes and intercooler piping are made of some shitty aluminum😂 some are nearly impossible to clean

[@patrickscycleshop]

looks like 25 Magnus employees have dislike your videos.....Great video.

[@eddiebushell176]

Now me and the mad scientist gotta rip apart the block, and replace the piston rings you fried!

[@JohnDoe-mt8rf]

Amen! Been doing this for 17yr.

[@rubenpelayo1836]

Love that JG tig holder... (Jimbos Garage)

[@davidtyce2269]

Great video merril haven't talked to you in a while still kicking ass

[@bluegizmo1983]

I've always been of the opinion that after my talks with the customer, and a price was agreed upon, say for example I quote the customer 3 hours of work, even if it takes me 6 hours because I ran into issues, the customer still only gets billed for 3 hours regardless if it was my mistake in underestimating the time needed or if I ran into material issues out of my control.

[@snikwad003]

Next video: him and mad scientist riping apart the block to replace the fried piston rings

[@altonb93]

Yup the best customers to have and keep are ones that just tell you to do it no matter the cost😁 Those are the ones you always do the best work on and go above and beyond for. Sure you should do that on all work but most people are cheap and always in a hurry so you just want them to leave lol

[@gregkral4467]

Love your channel dude, and you nailed it.

[@michaelroof1969]

OMG, he said dookey!!! love it.

[@blackout7615]

Great repair! Imagine doing this repair if the manifold came from a diesel. Combine the oil from the turbo and EGR soot and you have a mess inside, that as it cooks off, will cause weld contamination.

[@antoniovazjr6297]

You are the best teacher

[@chadmoyer1453]

It's fixed and that's good. It looks decent and that's good.

[@stuartbreeden5019]

It's from the same engine that he was talking about blowing the welds on too 😆

[@paulkurilecz4209]

Nice presentation.

[@heatherrigby7371]

Brilliant as always

[@JimbosGarage]

Good stuff Justin! I like the Tig torch holder! By the way, My 42'' Atlas is very similar to yours.

[@irusvzi]

Lmao “danger to manifold” that’s perfect

[@wtfftw24]

I think you went a bit too high with the temperature but I am sure it will hold better than the original.. Good job as always👌👍👋

[@JTL-DK]

Not just OCD but i'm pretty sure about ADHD too! I have been watching a lot of your videos and there is no doubt about it! :-) You are amazing to watch and i really enjoy watching your videos, i am looking forward to watching more videos from you :-)

[@jimc4731]

You could use a multi position vise, similar to what jewelers or wood carvers use, but much larger. You could design and make your own and sell them. JIM

[@jondoe6618]

You are a great welder. Wish I could sit down and learn a thing or two from you. I am surprised you did not clean the inside of the intake of all the oil that is inside of it.

[@ldnwholesale8552]

Amount of carbon and oil in the intake was your problem! 40lbs of boost is probably 10lb of reversion

[@walkaway6353]

Nice catch!

[@wtfftw24]

I do agree

[@ChrisWojnarski]

Thanks Justin for the great video and helpful info

[@raulduke85]

Nice video, but apart the fact that your repair bead is more unconsistent than the original 1 (but it's a repair so it is what it is), I don't like people talking trash to someone else job, or skills

[@tonybason4929]

good job tell them like it is& tony from australia good content thanks for your input

[@sethamoto9061]

Good work!

[@christians131]

I appreciate all the talking he did haha. Are those just regular flap discs or something specific to aluminum like if he were using a grinding rock?

[@ralphwaters8905]

I thought you'd remove the throttle body to clean up the inside and flush out that crack (acetone then air) so it was clean and no abrasive dust remained inside. I wonder if the floaters and junk you saw were pulled in from the crack or the back.

[@michaelgrubbs1618]

I didn't see you drill a hole at the end of the crack

[@charliemclaughlin1042]

You did a great job

[@weldHAGOJIBI]

That's a great video. That's great.👍

[@dave0110aaaa]

I may not have caught you saying it, but what type of metal was the intake? 6061 AL? What was your filler wire? 3/32 4043? In a situation with a part like that, us beginners may not know anything about the part, how do you determine what type of aluminum it is and what filler wire to use? Thanks! Great video.

[@mikeford963]

4043 is the easiest to TIG weld aluminum. It works well because aluminum filler metal mixes with the parent metal.

[@dave0110aaaa]

Thank you. But I was trying to figure how how he made his determinations. I kinda know, but was hoping he talk through that process to make sure I got it. Again, thanks for the input as it confirmed what I assumed! @@mikeford963

[@mikeford963]

@@dave0110aaaa 4043 is the most commonly used of the filler metals. 5056 is the other one and it can be a challenge to weld with.

[@TheFabricatorSeries]

I used 1/16 4043. You can always add more from a smaller diameter wire, but not always less from a larger one.

[@dave0110aaaa]

Thank you! In a future video can you talk about your process for how you determine the metal and filler for repairs? What do you do when you are not sure what metal the part contains? Thanks and great videos!

[@OldDirtGuy]

Brawndo hat! Awesome!

[@laiky71]

Hey Justin, tell us about that back cap!

[@pollepost]

Nice job. Do you ever experience problems with particles from the grinding or flap disc get in the metal and destroy the weld?

[@dougankrum3328]

particles...yeah, there are some petty good abrasives and carbide burrs just for aluminum...most of the 'steel' abrasives aren't a good fit...

[@tomthompson7400]

very good video , not every repair job is perfect , but then again , if it was perfect the first time it wouldnt need a repair , its hard to go in after some one else has been there , and time and use have taken their toll on a part too. very honest job. trouble is , how do you charge for it .

[@darcymcnabb9259]

Miller blades for grooveing out welds on aluminum.

[@davidjanuszewski5020]

Thanks, very good info.

[@justinmalone9721]

The quality of the factory welds surely contributed to this failure. However, analysis of this geometry as a pressure vessel subjected to fluctuating loads, I would not expect the product to perform for too long without succumbing to fatigue.

[@chadmoyer1453]

Was you using acetone to clean from beginning? Great tip on masking tape. Former boss always said to me, "you'll see one day when you gotta buy it." I just smiled and kept ripping tape. He had big money n I wanted to do good work. Thank God.

[@superduty4556]

You owe me a 10 second weld.

[@janusszakazu9318]

Cool video bro. P.S. I hope you will give us more videos like that and more often. Thx again.👍

[@ejbrandt9736]

WHY would you leave that throttle body bolted on to the intake? Its just a few bolts to remove? Then you can use the threads on it to bolt it to a fixture? Other than that great job!

[@briandonaldson9906]

In order to stop this from happening you must have positive and negative amperage control in the machine with a proper weld ending, its absolutely necessary and if you don't know what I mean well sorry I'm a level iii aerospace welder and know the exacting science.

[@Mikael5732]

@@douganderson7002 I think J used his Fronius machine beacuse it was lit up at the end of the video. And I am sure he had his +/- balance set right. I was trying to figure out what the aerospace guy was getting at. He was very general.

[@BlownF150]

When the intake was taped up, did you leave a hole somewhere other than where you were welding for pressure to escape? Not only will welding heat raise pressure in a sealed volume, so would the purge gas.

[@atmjcdsmaddict7897]

Plus throttle bodys dont seal 100%

[@LittleAussieRockets]

Good stuff mate!👍

[@dustinandtarynwolfe5540]

Those magnus DSM manifolds always seem to break there.

[@kinzieconrad105]

Exactly and if you can find others you might have a warranty case. Most probably trash and buy another and magnus has no clue or is doing-it just for that reason.

[@dustinandtarynwolfe5540]

It was well known 10 years before I got into dsms.

[@imcanika2715]

hi. i am Jaime from MEXICO.. Your videos are always very interesting and complete.. but in this case i would like to see the video or tips about the schematics or drawings on your weld table, i suppose there are about TIG AC settings, could you send the link of this or a complete review of the AC settings.. i can see 4 diferentes waves , balance and more like my AC DC Tig Welder, and you are an expert on this topics.. thank you..

[@Stephenc4877]

Do you test them with air pressure before sending it back out?

[@angelasmith404]

I work for a ORV manufacturing company, that does not have written quality standards for ROPS... though ROPS are federally regulated by SAE and OSHA for agricultural vehicles. Could you please decipher for the manufacturing process, what defects - such as a dent deformity at the CLR are acceptable under the regulations? Does this weaken the integrity of the ROPS?

[@johnnymissfire8464]

How would you do a pontoon repair? Would you purge it also? Any tips?

[@michaelmangrum5460]

Where can I find a plastic storage box like you use. It doesn't have to have compartments. Just a cigar box size plastic box will do fine. Been looking all over.

[@chrisduncan2626]

I know this is an old video, but where did you have your shirt made? I like it

[@jackreacher1963]

Being to hard on your self. looks good and it works. 👌

[@rjuarez4913]

How about using what I saw a guy on KZbin do, he was welding cast aluminum repair and used an adjustable pipe xyz adjustable hand rest. I will find the video and put the link here.

[@garrettjames9295]

Dont beat on yourself I've been there u try your best to clean up but u still get junk coming out. One thing that helps is cooking the part with a torch first.

[@kurtemigh9546]

Those old magnus manifolds cracked there constantly regardless of boost. They added some tabs to later revisions to help but they still cracked. I think a lot of older ones were mig welded too. Dont let Marco hear you say the quality is lacking from them being mass produced. Arguments for DAYS lol

[@TheFabricatorSeries]

I guess that leads into something else I didnt cover: You can argue, or you can act. Argument leads to nothing. One side says yay while the other says nay. It never leads to a conclusion that is anything other than people taking sides. Acting means accepting the problem and making a correction to prevent it from ever happening again. Even if the problem occurs only once, that one chance to learn and correct.

[@kurtemigh9546]

@@TheFabricatorSeries Egos prevent acting.

[@blaqlabspodcast5816]

Gotta clean the inside also. The oil vapor from inside will cause issues

[@legitgamesforlife]

6:10 jokes on you I had my iPad upside down

[@atmjcdsmaddict7897]

Why didn't you wash it throughly from the inside ?

[@anthonyromeo4655]

whats a good chart for sizing tungsten n filler to your welding job?

[@1970chevelle396]

40 PSI of boost is a lot.

[@southjerseysound7340]

I agree but In the past 2-3 years boost levels have gone through the roof,60+ isnt unheard of on 4g63 these days.

[@mikaelgaiason688]

Not really

[@johnsidor7744]

Need to know s I meshing from you Justin I can use a 3/32 tungsten and a and a 1/16 rod correct

[@4speed3pedals]

How is the R2D2 welder (A.O.Smith) welder restoration coming along???

[@eland1981]

Is it possible that the dirt on the inside of the manifold is also coming through? I know nothing about welding TIG.