Tig Welding Cast Aluminum Outboard Jet Pump

For tig fingers visit my store here ...weldmongerstore... see the full web page on tig welding cast aluminum here goo.gl/k8QAH0 Tig Welding Cast aluminum on a jet boat part...its the jet pump for an outboard motor.
The worst cast aluminum weld repairs are usually on oil soaked parts like crankcases.
This part was only exposed to fresh water so it welded OK.

[@ThisOldTony]

love it!

[@bcbloc02]

One of my favorite videos you have done in awhile, it was a tricky piece and you got to touch on lots of subjects in getting it fixed back up. This is a whole other type of welding vs stacking dimes on some new shiny plates.

[@KnolltopFarms]

I agree, and really enjoy the "real world" jobs. I think they illustrate a worker's skillset more accurately as they show the troubleshooting and adaptation required for the individual scenario. Speaking of videos I enjoy...ahem, whatcha got in the can for us Mr.? Everyone who enjoys real world metalwork should check out this guy's channel^^^ bcbloc02 for the win!

[@bcbloc02]

Knolltop Farms Uploading now, please standby. :-)

[@tomherd4179]

Your "shameless plugs" are NOT shameless at all. Try looking at some other welding videos where most of the video is nothing more than a vendor's plug. You provide educational welding information! Thanks,

[@princetikki]

the "shameless plugs" are one of my favorite parts of your video, they always make me laugh and seriously consider buying it.

[@eddiekawecki2510]

I too would be buying them if I wasn't so frugal and just folded my own from boiler and oven door seal material.

[@eddiekawecki2510]

And I would keep supporting Jodi because of the great videos and info not to take anything away from him

[@jstrunck]

No doubt!

[@rileysgarages]

I thought it was a huge turbo when I saw the thumbnail for a second.

[@Faolan161]

It is... just moves water instead of air... 😉

[@Abom79]

Great looking repair with some good techniques too. Thanks Jody!

[@fredalmond9130]

This is something I would like more experience on. I do the odd repair job with my powertig setup but I think I would be much more marketable in my area if I was skilled at repairing cast parts.

[@AhmedAlsarraf]

best welding channel 👍

[@MyNameIssaSimon]

I can't be the only one that loves watching these videos without any welding experience at all. Except some mig but I can't call it serious experience

[@Shazbat5]

You are not! Right there with you.

[@MrDidgy]

sounds like you needa start welding.

[@lewiemcneely9143]

2nd that!

[@nielosoweznaki]

yeah, me too :)

[@lewiemcneely9143]

MrDidgy I'd likie to but am having to wait till a mig or tig rig gets cheap enough to afford. And I may be a tad too old and shakey to start BUT is sure is a nice way to do things!

[@Dionkrab]

Hey Jody i dont know how to get your tig finger and the XL, because i live in The Netherlands and i dont know how to use paypal or one of these other's. Is there a different way to buy them in a store in my place ? P.S. I like to watch all your video's. Thank you for being a good teacher, i have learned a lot from it. Have a good one!

[@joeblogs8345]

Jody, thank you for sharing your knowledge with us all, and doing it in a clear, well presented fun to watch way.

[@princetikki]

Just love watching your videos, feels like my dad is teaching me welding.

[@philipbarker7672]

I would like to be adopted by Jodi

[@WickedWood]

I have said it before, but I will say it again. You have a great ability to get information out to your audience clearly and thoroughly. Thanks for another very informative video.

[@vprinceii]

I had and oil pan that had a leak from the factory, manufacturing flaw. it had a pinhole leak at the drain plug. my brother in law was teaching himself tig welding. it took us two hours to get it seal up completely. it turned out it wasn't just a pinhole it was a very fine crack that was about a quarter of a inch. I didn't know about that spray to find the crack. we just kept welding and checking for leaks. it is still alive even though the engine died.

[@JohnBare747]

One of the few times I was happy to be given the finger, Tig-Finger that is, works great!

[@spelunkerd]

Love that tip, to pause and wait for the puddle to fill in. Things happen fast in aluminum.

[@Gkuljian]

I really miss doing this kind of work. Now I have to go break something.

[@eddiekawecki2510]

Great reply!

[@kenrubo]

So much going here in this video and I agree with the others, best welding channel ever, beautiful video-- top notch camerawork, editing, tips, even the tigfinger xl pitch was great.

[@tompas11A3n52KkX]

I have been watching your videos for about one year now and I must say your videos are always high class. Masterclass welding that is. Thank you for your educational videos and keep e'm coming. :)

[@XS400Seca]

Hi Jody, Thanks for another great videos, it is really nice to see some of these actual repair videos that covers what you might run into as a welder. I am only a amateur but I have learned a bunch from all your videos and your tips. Just had to weld a z-drive for a v8 speed boat and all your tips and tricks sure helps :) Thanks again for your great video and keep them coming!

[@shadowfox929]

Another informative video, thanks. I had a tig finger and just got my new xl-tig finger. I love it.

[@Edward135i]

I've got a neighbor who needs me to weld up a part of a transmission for him, I watch this video every time I need to do cast aluminum welding as refresher.

[@machinis]

Newbie tig welder here. How did it go? I tried welding a servo cap off a 2001 ford explorer and it was a disaster. I was so frustrated I threw the parts away when in reality I should have kept it to keep practicing.

[@BruceBoschek]

Good job and great video. Thanks for sharing this.

[@MakeEverything]

Great info! Looking forward to trying my hand at some cast repairs coming up! Thanks Jody!

[@oldpete3153]

As usual another 1st. class video from a top notch craftsman, my favorite channel and always looking forward to the next addition to the site. I just got my "Stubby-Kit" from Jody today and hope to try it tomorrow !!

[@MrQuietscheDUCK]

Wieder ein super Video. Again a great video TY

[@LewisRenovation]

you make it look so easy, which I know it's not

[@jonwoody3572]

That`s because Jody is a Top welder and a true professional & craftsman

[@miketlane]

glad you took this on, i get in arguments all the time where guys go off.... its cast!!"you gotta know what alloys it is and use special rods" "you gotta pre-heat the entire part for s specific heat and time" "then post heat with a slow cool". some people think welding aluminum is dam near magic that requires aerospace engineering and metallurgy degree and a shaman to weld it.

[@stevemackelprang8472]

I made my living welding, and I just learned a couple of things... thanks!!

[@setnbronco4932]

As always great vid, love these real world application vids. I used this technic on a FI intake plenum, it worked great. Keep these great vids coming, I am a subscriber and always look forward to them.

[@kalijamies]

Could you make a video about MIG welding with different wire sizes? The same weld, the same material (thicckness) but different wire size, 0.6 and 0.8 mm whatever the corresponding standard sizes are. Tips for voltage, amperage, wire feed speed needed for a solid weld with both wires.

[@fabianfraga4]

Hey Jodi i got an electrical question, what size brakers do you use for your welders , im building a small shop and was wondering what size brakers would be needed i have a precision tig 225, and an old hobart 251 mig, great vids ..

[@countryrecon8186]

Perfect for us in Florida TY! Im currently in Tulsa Welding School and you have been immensely helpful ty - helped keep me ahead of the curve.

[@Flightstar]

What's all this talk about opening cracks and slamming rod.. Doesn't sound very decent.

[@MakeItWithCalvin]

Really interesting technique but it makes sense. The cleaning action is there for a reason and you might as well use it! If you really want to make some nasty looking aluminum get some super high mineral content water (out in Cali were notorious for it due to our drought) and let that sit on the metal... you get all kinds of nasty stuff real fast! I think im going to try this technique when welding on some aluminum for a splash guard for a mill i have. My issue is i get a bit impatient and do not wait for the welder to make a clean puddle and go jamming rod in... you guess the rest ;)... keep up the good work on videos! novice welders like me really enjoy and appreciate them.

[@ls2005019227]

Jody, awesome video as usual, but the real-world application is icing on the cake. I have an outboard jet & aluminum boat, which was one of the major reasons for buying a tig machine (Syncrowave 210) recently. Thanks again for another great video. I would highly recommend the gas lense kit & tig finger combo to anyone interested; it's definitely been a helpful addition for me.

[@davidspin581]

Good video, down here in SW Florida I get to do some similar repairs. Old, salt water, oil and carbon soaked aluminum is a real treat !

[@levondecarlo]

Thanks for all of your help!! Too many BS welders on KZbin, whereas you keep things simple and straightforward...

[@mommemomme]

Greetings from Spain. Great video, great explanations, I enjoy learning from you. Thumbs up!

[@alansmith5842]

Just had a cast manifold from a marine diesel to fix it had rotted out where the injection elbow went on, had to build up some areas and put a new flange on then machined it and fitted new studs. Plenty of die grinder / carbide action to get to clean enough metal to light up on ! Your vids are the best Jody thanks.

[@albertcasp]

excelente vídeo es el mejor canal que e encontrado de este tema es de mucha ayuda le ayuda a resolver muchas inquietudes se le agradece por tan buen trabajo estoy muy pendiente de sus videos

[@LambertZero]

Must be a really good friend of yours. :-D That was a lot of work I bet.

[@KPearce57]

In that business "One hand washes the other"

[@michaeldunagan8268]

The second "hiw to weld cast aluminum" video tidaym. Bad torque wrench or Ace hardware nut and washer split the aluminum flange on my 1999 Titota Solara 3.9 V6 1mz-fe intake plenum or as Tiyota Workshop manual calls it:"Air Rish Tank". O deem your video more informative on a variety if task relative to the first video where he pretty-much let his TIG-ing doe the walking.

[@masonsmith7018]

This was a great video to watch. Very informative for a 2nd year welding student like me to watch. Thank you for making a video on TIGing cast aluminum

[@godfreypoon5148]

OK Jody, how did you know to make a video on exactly what I had to do and was a bit uncertain about?

[@davidstonner]

Is that a coil of copper tubing on the back side of the huge shop fan in the background of the Crackcheck shot? Can you explain what's going on with that? Looks interesting.

[@bozly209]

This is one of the best voice over tutorials I've watched. I'm not a welder and I understand what your explaining. No background music is nice. You seem like a great teacher too. TY sir.

[@ovalwingnut]

A Jet on the end of a outboard? BLASPHEMY!!! Actually, I have no idea but it was very COoL (yes, the welding too:)

[@frankfromupstateny3796]

Love watchin experts in any field....if we could just stay young for a coupla hundred years....and try more things....ahhh well.

[@louiskealiisantos602]

Hi Jody! thanks for the vid. I has a question about my new project. Its a aluminium pontoon boat. There are cracks in it. I currently have a lincoln 110V mig w/ spool gun set up. However, Im wondering if i should get a tig. As i know my mig, i tend to burn through on thinner aluminum. The pontoons are 1/8" thick. lmk what you think please. Mahalo! Lou

[@alief4935]

amazing video! thank you so much. just wondering what filler rod you used for that. actually where i live it's very common to weld repair cars cylinder heads, so im curious what is the best filler rod for these kinds of jobs.

[@martinmaurach6422]

What was the filler? 5356 or 4043?

[@weldingtipsandtricks]

4043

[@luckybambooguy6084]

Excellent video the camera shots made it very easy to understand and learn... Thanks Soooo Much

[@davidthorne6796]

Awesome!!!!! Right on!!! I want to make a jack play like your buddy's got there and had an old fellow don't four 18 inch pieces of 4 inch aluminum angle... I'd have to measure but I'd guess little thicker then 1/4 inch... but there about in thickness. I'm just going to add a piece of 2x12 for the motor to clamp too and by having one set slightly wider I can add elongated or several holes to make it adjustable on the up and down by tightening four bolts... I want to add like 3 inch bar stock or plate at the top and bottom of the transom side of the two brackets to spread the load and it will also keep everything together and square should I need to remove the unit. What's my best process based on this info... I'm thinking tig welding might be the way to go? Maybe drill four holes in the brackets and kinda spot weld those to the bar stock or plate? It's only 25 hp so it doesn't really require massive strength... but you wouldn't want to loose it either!

[@ExStaticBass]

I've done a lot of welding before but not much TIG. How much does frequency really effect temperature? I've done lots with a stick and plenty with oxy acetylene. I've even used a MIG before though I didn't like it too much as it didn't seem like I had much control over it. There was just too much to fiddle with. That's why TIG interests me so much. It's the precision of it. I just got done watching a guy weld a soda can back together. Something like that I can get behind and run with it.

[@larryfry1310]

Are you assuming the casting is 356 aluminum? If so, what alloy filler did you use....4043? Some good tips in this video.

[@EastCoastWoodworking]

Jody if the part was in salt water would you just not weld it?or how would you go about it?

[@weldingtipsandtricks]

Salt water part might be only slightly dirtier. I would have taken a shot even if it were oil soaked. Might have taken a bit longer though

[@PowerBoostComAr]

Please add shipping to Argentina on your web site... I can't buy any or your kits right now.

[@powertothebauer296]

Good Job Great Video. If you warm ab the Cast Alu you don't need so much Current. If you can Adjust the Current Flow on Ac you also can go a little more to minus so you get more heat in the Casting. That is a good Tip ,try to weld with the minimum possible Current. This is what i have to talk every time to my welders.Warming up also minimises possible Cracks after welding.I think i have to show your video for teaching my guys in the Workshop

[@cnhman20081]

Do you recall what alloy filler rod you used? I have a jet pump I need to weld up. Pretty much identical to what you had there.

[@MakerTable]

How do you get such clear shots of the arc?

[@danielsplayhouse3804]

I follow a lot of your videos Jody and me I'm a noob at doing this and I started off with a with a multi-process unit that only did DC and I started off doing steel and stainless steel and I ended up with a machine from primeweld AC/DC machine Tig 225x. the machine opened me up to aluminum and I took to aluminum like a cow to water and that's what I've been basing all my work on is aluminum work and like you're showing on the cast of aluminum is that where the bulk of the money is cuz I've been seeing that my pockets have been getting lined a lot easier by doing aluminum work then doing steel repair or stainless steel repair. and on that note I also noticed too that people are willing to pay a lot more for aluminum fabrication then stainless steel fabrication. is that just how the industry fluctuates back and forth or is that just how the industry is in general?

[@jessesouza94]

About to repair a cracked rear differential for a Miata. I’ve been doing some research and can’t find anything saying clearly if I should pre-heat and post-heat as well as peen the weld to prevent future crack. Any advice would be great, thanks!

[@noplease2608]

I'm sure you already made a video regarding welding somewhat thin aluminum and stainless steel parts, but I am curious to see what videos you have and tricks and tips for doing it. The current projects I am working on is modifying a contractor top for my truck where I have to shorten the length of the top which is all aluminum with aluminum frame "the frame is what im going to be tig welding once the modifications are done." The stainless steel project is for a grease catcher that someone wants me to make for them because buying a new one is apparently expensive at around 1k and would be cheaper to make one. The reason why I ask is because it's been nearly a decade since I TIG welded anything and I am basically coming back at this brand new in terms of experience in memory.

[@cdavis9935]

I weld sub powerstations, casted alum parts to 6063 3"+ pipe. Get the fingers....

[@ParadigmUnkn0wn]

Was AC balance discussed at all? I may have missed it, but I don't recall hearing the setting mentioned. I'm curious what you ran for this part.

[@superiorwelding]

Great video as always Jody. I think I prefer cast alum over cast iron any day. I switched to the 4943 for my cast alum repairs as well. My machinist customers like it a whole lot better. Jonathan

[@weldingtipsandtricks]

thanks Jonathan, I visited my LWS the other day and scored some free 4943. Its been on my list of things to try for quite a while. I got home and tried some and I like it a lot. flows good, wets in nice, and has good mechanical specs.

[@ryanjones9305]

+weldingtipsandtricks I got some 4943 to sample and I was noticing a grittiness to the appearance of the finished weld bead. I've seen the same off and on with other alloys and have looked into a bit but can't find an answer as to what it is. The metal was prepped properly too, the rod clean, good shielding gas, fresh tungsten. It may just be me, but I've only experienced it with my inverter machines, never on my transformer ones. Have anything to add to that Jody?

[@weldingtipsandtricks]

4043 can have the same grittiness. I think cooling rate really affects this. slow cooling rate seems to have a gritty appearance and quicker cooling rate seems to have a shinier appearance. I suspect slow cooling allows different phases to form. not necessarily a bad thing ...but an observation nonetheless

[@ryanjones9305]

+weldingtipsandtricks that is a new perspective on that. Makes sense. So that probably means that I'm overheating the base metal then. Maybe an experiment is in order....

[@joachimsingh2929]

Anolimion sure is hard. I've never welded amonolimum but it seems pretty valuable. I guess I'll get my chance to try som anomilum in the future.

[@panther105]

Repairing broken parts that have complicated shapes is really interesting. So clear the true value of welding in cases like this.

[@JMRSplatt]

I know it's an older video, but that huge shop floor fan you have, spotted around 1:55, I noticed it has some copper tube coiled up? Is this a sort of portable AC unit, but not a swamp cooler? It looks pretty neat and wasn't able to find much online.

[@ScrewDriverxxx]

Just another quick thanks Jody. One of the things I really like about your vids is when you say stuff like "Hi, enough chat, lets get on with it". If only a few other KZbinrs would do the same! Really useful info again thanks.

[@AsifAli-fx1vi]

Very good picture quality and explanation about any job and clear and complete visibility molten metal during welding , supper sir

[@nelsonsantos770]

Always love watching your informative videos! Thank you!

[@4570Govt]

Jody, are you going to FabTech in Vegas this year? This will be my first year there(going as an attendee), would love to meet you if you're not already swamped with a line of other folks who want to do the same!

[@jca66]

Talking about oil soaked. I was just repairing a turbo housing out of a diesel truck today. I guess google heard me and recommended this vid. I love doing cast. I also deleted an old waste gate on a cast iron part with brass brazing.

[@theoldwizard998]

Other experts have said the same thing. TIG welding cast is very much like brazing.

[@awm8158]

I'm not a native speaker. 7000 series unweldable ? Is that what Mr. Tig said?

[@Mr99dm]

What rod did you use for filler material?

[@weldingtipsandtricks]

4043 on the actual part. But then I got some free 4943 at my LWS and tried it out for the mocked up arc shots. 4943 was nice and might have worked better on the part

[@jacekgajda9582]

Hello Please tell me how strong tig I should buy to repair aluminium rims? Greetings from Poland !!

[@1967duetto]

Great Vid, I also like the real world applications . I have to repair some corrosion on a old English alloy Cylinder head , Any Tips ??

[@mrjodoe]

3:42 - if your carbide burr jumps too hard, try only pulling the tool. Jumping will stop.

[@troymorrison3623]

Thanks Jody , another awesome video well done

[@dr.feelgood2358]

just noticed what looks like a fan in the background with copper coiled on it. is that hooked up to a water pump or something? JD's shop i'm guessing?

[@customhaines2510]

What filler metal do you recommend for cast aluminum? Just did a bird bath for someone and it was a mess, I'm wondering if I should have used a different filler.

[@theoldwizard998]

Keith Fenner pre-heats his cast iron parts to remove oil contamination prior to brazing by "cooking" them inside if his wood burning stove for a couple of hours !

[@hollandhilton5763]

Awesome video thank you. have a question got a guy that has a Honda motorcycle motor with 2 motor mounts broke off it is cast alum. What would be the best way to do this job?

[@stevepeat1719]

Hi Jody-what was the AC balance? The tungsten seems to keep its point,doesn't that mean more -ve? cheers

[@arsenicneptune9998]

75%ish DCEN

[@PeterWelder]

Thank you very much for this nice video. Did you use ER4043 filler rod ?

[@paneerdog5623]

What about painting the finished weld with tempilac and heating it until it melts? Is this avoided by using the er70 rod rather than chrome moly filler metal?

[@C71-m1l]

I cant buy that leak dye in my area, so what I use is some kerosene with food coloring in a spray bottle and some dr scholl's athlete's foot spray. It works like a charm.

[@Brainmalfuction]

Dam a day too late, I just did a gear box for a tiller... Man it was dirty shit you could see like black honeycomb eating out of the metal.

[@markrich3271]

I've said this many many times. My Mill My lathe and my tig welder were all very expensive tools for me but they have paid for them self many times over and over.

[@g.b.5206]

Hi, I need it to fill a small hole inside my power washer engine created by the road holding the piston, I was thinking to use the selfing flame and aluminum rod, would I be able to or I need to use a big welder? I'm a beginner

[@vanmann8347]

Your friend is lucky to have you because you just saved him a bundle.👍

[@taylorsecreto9526]

finally decided to by a tig finger XL, hopefully its worth the money.

[@conradjordan1222]

One of your best videos!! Thanks!!

[@shionhaggi8163]

why welding with aluminium electrod have no good shape and form?

[@ChrisB257]

Another super instructional video Jody - thanks. "Washing" - good description. Not sure if mentioned - what might current have been on the thin section.? Love my large tig finger.

[@weldingtipsandtricks]

I would guess between 125-150amps on the thin section

[@AbuKassimMohdSaleh]

Thank you sir for your TIG welding lesson, very nice video.

[@jpcallan97225]

Another especially well done video. I hope you will answer a couple of questions: 1) Do you have one of those Fisher Scientific Niton XRF xray fluorescence guns that measure the elements in a metal sample so you know which filler metal to use? 2) I'm going to guess, based on how well the filler rod wetted and flowed, that you used 4043 for this job. Am I correct?I bought a few of your TIG Fingers and TIG Finger XLs; very userful. There is someone in China ripping you off on eBay (see 182196830265) advertising your product by trade name and using the Weld Monger name. I hope you stop these people, file a complaint with eBay or something. I'm getting really sick of the continuing rip-off of U.S. businesses by got-no-morals Chinese businessmen.

[@weldingtipsandtricks]

4043 on the casting but I got a sample of 4943 from my lws and used it on the mock up shots and it flowed great. I plan on doing some testing on both soon. as for the chinese knock off folks, thanks for the heads up...I am in the process of filing complaints on ebay and amazon. these folks are even using my images and then showing their inferior product last.....

[@jpcallan97225]

While I watched this video about a half hour ago, I had pop-ups from eBay and others on the right-hand edge of my screen touting the inferior knock-off TIG Fingers and trademark-infringing references to your company, so maybe KZbin has something they can do to at least suppress the Chinese advertising on your videos.

[@davidthorne6796]

That's really terrible stuff ripping a cool dude like you! I'll pray for some swift justice for these terrible folks! I mean it's obvious that you're main motivation in creating these helpful videos is to help us less experienced folks have success! KZbin should have folks jumping right on this for fear of you getting angry and ceasing to produce your excellent videos!!! You have by far the best training videos on KZbin!!! Your help in like having a big brother to show you the ropes and get you going down the right path to practice and then success ! Thanks again, Sir! David in Pa

[@mrjodoe]

hey jody, does the housing still work today? greets from germany

[@hammershigh]

What kind of filters do you use for your recordings of the arc? And what camera?