Weld Repair with a Budget?

Here's a fun one! Can this repair be made for less than the cost of a replacement? Sometimes you just have to make the decision as to how much you can do. In this instance - it's all about how far Justin was willing to work on repairing a cast aluminum turbo housing.
Save 10% on welding consumables and practice metal with code TFS10
weldmetalsonli...
Learn to TIG Weld in Our Class!
thefabricatorse...
Check out RecklessRegal's Channel
/ @recklessregal
Subscribe to The Fabrication Series for MORE!
Check out the website: www.TheFabricat...
Like: / thefabricato. .
Follow: IG @The.Fabricator / the.fabricator

[@TheFabricatorSeries]

Save 10% on welding consumables and practice metal with code TFS10 weldmetalsonline.com/ Learn to TIG Weld in Our Class! thefabricatorseries.com/classes

[@RecklessRegal]

This came out perfect! Thanks again for getting it taken care of under budget and on time so I can get back to installing the turbos for my next video.

[@Andrew-hh3ol]

How did it break

[@RecklessRegal]

@@Andrew-hh3ol Turbos can't fly.

[@tfr6]

@@RecklessRegal I was just about to test if they can. Darn it.

[@RecklessRegal]

@@tfr6 0/10 Do not reccomend

[@Andrew-hh3ol]

@@RecklessRegal very sad

[@jackbrimstone1004]

A tip that goes a long way with grinding aluminium is to use some bees wax or even a simple candle rub it on the flap disc or flap drum when its running, this both saves the disc from disintegrating and stops it frok clogging up so it cuts easier.

[@dontnubblemebro]

Soap works too!

[@ArcMastersLLC]

I religiously do this and also always get covered in wax. Lol

[@petersmart1999]

Plantex Tiger shark flap discs and Kanga roo oil! Amazing fast cut ,no clogging

[@dylanskeavington1336]

Also for files load them with soap stone dust it it help with the gauling of the aluminum

[@CarsAndCody]

I think one of my favorite parts of this video, it’s showing that the final product can still be imperfect us however the customer sees it as a perfect repair but we just critique ourselves more than most people do! This is showing that it’s OK for a repair not to be absolutely perfect which I think is a very valuable lesson to people especially knowing what the repair is for and what piece is going to be doing not everything has to have a picture perfect repair! It’s just a matter of your own quality control and level of perfection that you strive for

[@ModelKing1000]

as someone who has just recently gotten into this trade, this perfectly describes my struggles that I'm trying to overcome.

[@LonTierney]

Great explanation of the waveform and process to repair. As that’s the intake side of the turbo, I’d opt for the free repair of just putting the coupler over the damage and moving on… :-)

[@thewespaul6520]

Right?

[@RecklessRegal]

There is no coupler for this turbo, the damage would be visible at all times. Even if there were a coupler the damage would have prevented it from seating correctly and thus sealing.

[@RambozoClown]

@@RecklessRegal So the repair will be visible at all times? No coating makes it look pretty bad, and recoating would blow the budget.

[@samruba7441]

@@RecklessRegal I don't think most people run their turbos without filtering the intake air

[@RecklessRegal]

@@RambozoClown Yes it will. Recoating has to be done either way, whether a new housing was purchased or this housing was repaired and was not part of the budget.

[@spudatbattleaxe]

KZbin is pissing me off this is the second time ive had to manually search your channel only to find that ive been unsubscribed and missing out on your latest vid… (and i know for a fact i have never unsubscribed!!) idk whats going on. But i do enjoy your videos and the techniques and experience you share! Have helped me out on a few personal projects ive had for sure.

[@Lurkzz]

Okay this one helped me A LOT! I've had this thin cast part at work that has been giving me trouble and changing the curve manually like you did worked wonders, I only thought I could change the times at +/- and not the amplitudes.

[@Spelter]

Nice repair. I would have looked it I had a pipe with the inside diameter as it's outside, so I can stick it in there and then reshape it with the original material and then just weld it shut. The hose of the turbo forgives a lot. But the trick with the waveform is gold, I never heard that before. Thank you for showing us!

[@devicemechanix9049]

Great one! Loved the explanation of the waveforms.

[@TorquinDSL]

I very much appreciate you taking the time to make videos of your various repairs. The are so informative.

[@kdahm1]

I just watched you in my brother Rob's video when you helped save his Vette from dropping some Doritos on the floor. Ive learned a ton of welding shit from your channel so to see you pop up helping and being so kind made me smile. Thanks man I owe you a drink!

[@danielsplayhouse3804]

Finally got a hold of one of the primewell tig 225s been trying for a year great machine great great machine told myself how to weld aluminum welding my stainless steel even better than my scratch start machine love to see you do another world with me live course

[@wwhb4780]

I vowed never to try welding aluminium again, and I kept the promise for more than fifty years. The xxxxx aluminium dripped down into my shoes when I tried the first time. Today's inverter welding machines are really great. Even I did not manage to set the house on fire. For Iron only :) .

[@mixedboi]

The work that you might not be very proud of, is a hugely professional job for others.

[@notsure8012]

Wave info was above and beyond. Thank you.

[@bloody_pinata]

I'm not a welder, but love to learn about the process. This seems like some next level thinking to me. Super cool

[@TheNigel55]

Iam a ally tig welder it just takes a lot of practice

[@dhanwatiesukhai2524]

Awesome repair job. Very well explained. Thanks Justin.

[@inssan6550]

Be very careful with wire brushes, don't use the same one on different materials, they'll introduce contamination. I have different brushes for aluminum, brass, steel, and stainless steel, and only use them on the same material, steel and cast iron seem to be OK together. The brushes pick up from the parent material and then spread it on to the next job which can cause havoc, especially where welding is concerned. Don't use a brass brush on steel,, it will coat the steel with brass. Stainless steel brushes are OK on most things because they are so hard, but they'll pick up brass and then transfer it to other material, Etc. Another great video, thanks Justin

[@CurtisLucara]

Nice job Justin, hey my kid just showed me your Instagram post about some scumbag who stole a Tig Cup from you, we just want to say it wasn't us and you were more than hospitable to complete strangers from out of town, unfortunate that this happened to a cool guy that opens his door to strangers and treats them like family in the weld community, we had a great time there and just want to say don't let this scumbag get to you, still more good people out there than trash like that, we are bummed for you, but don't change because of him, your to good of a guy for that!

[@middleway1885]

Much respect to you keeping to your standards... Cheers!

[@ifitsnotbrokenfixit1193]

Thanks for sharing Justin. Came out great matching up the colors will be the hard part.

[@RecklessRegal]

The whole piece will be stripped and recoated.

[@dwaynemadsen964]

Thank you for sharing. Also, thank you for talking about the trade-offs, cost vs cosmetics, or however one might choose to phrase it. Also, loved the subtle reference to the toxic commenters! Stay safe.

[@jamesb43]

Amazing to come in under budget on that!

[@mohgujai]

Why not chuck it on a lathe for the final finishing? Would've looked a lot better than freehand

[@sexyfacenation]

Does he have a lathe?

[@kcscustom9759]

Yes but it would have took longer. I mean a pro probably could have knocked it out in the same amount of time but from what I recall he doesn’t do much work on the lathe

[@kevinsundquist1989]

I don't think his lathe is big enough for a turbo that size and he prefers to show the simple hand tool methods on his video's so his viewers can see how to do it at home

[@permagrin8742]

Time is money is what this vid is showing. Time spent to Chuck up and tool setting would blow the budget. I thought he was going to section a piece of tubing in myself. Then lay a head to remake the lip.

[@peterspencer6442]

@@permagrin8742 I agree it's a large awkward piece and setting up is everything with lathe work; I also would worry that the tube may be out of round just enough for the lathe to start wanting to cut into good metal elsewhere before the weld cleaned up and it would therefore still need hand finishing, adding more time overall.

[@codys_fab]

Great video. I've really been enjoying these recent repairs. Keep up the great work! 👍

[@nilnull5457]

These videos are satisfying to watch.

[@mcqcjc8409]

Hey I had to weld a new outlet to my radiator and it is 28mm diameter and 1mm wall thickness..maybe 1.5 What i found problematic was the fact that i couldnt make the thicker radiator wall to melt without melting outlet so i ended up building up material on the outside of outlet with lower current and then joining everything afterwards What advice would u give on joining thin walled pipe to a big thick heavy section of aluminium that draws all the heat? Thanks

[@nicolec7290]

Nice job

[@khalidkk8998]

I know this is off topic,but man your voice is so soothing. Outstanding job nonetheless.

[@jimgam730]

Nice job on this repair.

[@justmemyselfandi5532]

100 bucks per hour , nice m8. I would not weld that housing, I would just bend it back it it wants to be bent with some heat and all is good. Different story if it was not mine, then I would buy new one. Thank you for sharing your wok, much appreciated!

[@FM-xs3vd]

I think he used a triangular wave form because it matched the shape of the cut out portion.

[@stevesloan6775]

so informative

[@PBMS123]

3:40 its better to describe the work done as the area under the curve, or he area each of the wave forms generate, as it shows how the whole shape affects the work not just he time at peak

[@wcmwfab935]

Another great vid. Thanks for posting brother.

[@louisfkoorts5590]

To the "Fabricator". Job well done. 👍🏻 Looking through these comments... [One see why you often find vehicles that look as if chunks were bitten off and spewed out. If you use the loo, flush afterwards. Please.] Dignity and some pride.

[@danl.4743]

Really enjoyable watching you fill that gap. I guess that's what people these days refer to as "satisfying"?

[@HFG]

A KZbinr mentioned in a relatively recent video that he was charged $15/inch for aluminum welds. I never heard of being charged by the inch. He's in Canada.

[@ssnydess6787]

Could I have used a copper or steel backer inside the tube? Soup can metal? Thanks! appreciate the triangle explanation.

[@DCweldingAndArt]

Great job Justin! I miss these in depth repair vids! My favorite format. That magicwave sure shined and has earned its keep 10 times over by now! I remember when it was brand spanking new :) now ur posted up in a fine studio talking on a million dollar mic with a gold 100 bill on the wall lol like a boss! 👍see u at FABTECH I hope! Dcweldingandrepair/Derrick C. I'll be there Wednesday and Thursday

[@christophersuttle4007]

Where have you been?

[@harryazzole7814]

I wish there were competent fab guys with the rates you have near me. I always need minor to medium jobs done and have yet to find someone.

[@c.mikelongo6628]

Great work.

[@garyf5192]

Very good, and helpful about the waveforms.

[@SabreCycles]

72 minutes... 40 minutes in the reading room, 5 minutes welding and 12 minutes prep and finish.

[@Day11film]

hi, thanks for the videos, they're very informative and helpfull

[@sku300Fi]

nice content as always. Hope you can upload videos more frequently

[@mihailpetrovici5044]

I wouldn't have done anything to than. I would have either break the part off so it doesn't fall in the turbo or just jb weld it so it doesn't fall into the turbo. That side doesn't see pressure and the crack wasn't far enough for s coupler to not be able to cover it

[@TheGamersRace]

I wouldve just filed it smooth so it didnt cut my tube.

[@sangetsuichigo7981]

Question sir . Can you weld a scored sleeve of a block? Then hone it to get flat surface

[@brandonlee-officialmusic2790]

Merril! I'll be in town this week! Chop off my dpf on my 2500 duramax for me :p lol!

[@Ryan_1997]

Hope all is well bud🙏🏼

[@905thomas]

Great video

[@chriso1373]

Cool feature on the machine with the different waveforms. Out of curiosity, could similar effects be achieved by using a machine equiped with a/c bias?

[@TheFabricatorSeries]

Yes.

[@chicagorc3967]

can you please add a extra camera view of your foot pedal movements. I really enjoy your videos and i think it'll help people with the explanation.

[@carrestore]

good job bro 👍👍👍

[@ifell3]

I like showing basic tools so I use my cut of wheel, then bang I use a welder with goofy settings aha

[@dontnubblemebro]

But you don't need those wacky settings, they make it easier. I'd probably run 50/50 or less, but with pulse as well. Most AC/DC TIG inverters will let you set that up.

[@wtfftw24]

Cool and good job. The problem, here in Italy, is that costumers pretend a perfect job so that those small imperfections must be corrected sending me out of budget... 🤣🥴 I mean it's often easy to do a under estimated preventive..

[@chadillac3006]

Can you try out the Weldpro Digital TIG 200GD i just bought one and has nice features and actually think it will give the primeweld a good run for the money and it only weighs in at about 40 pounds makes moving around nice. Bought it on amazon and shipping was really fast came through UPS in 2days of order. My only con with it like other none high end everlast welders is cant run E6010 rod which 6010 is still the best stick rod around :D

[@DavidRobinson-mx6cl]

Do one on cast iron !!!!!

[@johndeninger8905]

great video pal👍👍👍

[@joesquickblips6612]

I love your video and learn a lot. I work welding aluminum windows and we don’t use a pedal. It’s difficult sometime because of the way the windows are shaped. Any tips on no pedal TiG?

[@bliviont]

He clearly used a negative triangle waveform because he removed a triangle shape from the piece. 👩‍🏭

[@joell439]

There’s always something more to learn 😜

[@jasonkeith674]

That was a great explanation. Than you. I did a repair on my transmission bell housing last week and it just kept becoming black. Now I know why. Do you have a link to your sanding/grinding materials used? I could have cleaned and prepped better for sure. Thanks again for your videos 🙏. Also, how is your Primeweld 225 holding up?

[@eduardleschinski2982]

Sehr gut!

[@irish-thinker4429]

Did you ever finish the turbo bike ??

[@alasdairhamilton1574]

Paint comes as extras 😃👍🏴󠁧󠁢󠁳󠁣󠁴󠁿

[@beleg1437]

Do your classes have anything to offer for a welder that understands the puddle from burning stick on B-pressure pipe for a long time and has tig welded a couple of Al fuel tanks over the years?

[@johnops1653]

I need coolant what's good and cheap for long island NY it freezes in my area

[@Carmelldansen4eva2]

Could've pulse AC tig work instead of manually moving the pedal? If it wasn't completely applicable that makes sense for how thin it is just wondering.

[@Dcale]

Fireball tools dispelled that myth with the file

[@user-oj4xh8cg2l]

in what would that dual curve wave be significantly different from a non 50/50 duty cycle ?

[@mattnsac]

A 4 jaw in a lathe would have that contour done perfect and in a fraction of the time as using burrs and sand paper.

[@simpsons5050]

Awesome guy

[@jerseycasull4546]

It's aluminum, why didn't you just bend it back to shape and clean it up?

[@HaloHamstur]

Aluminum isn't good to bend, it will crack and break.

[@brycegrebner3977]

Won’t even notice the imperfections after we coating it

[@brycegrebner3977]

And after the hose it on

[@RecklessRegal]

@@brycegrebner3977 There is no hose to go on though.

[@petrrieger2680]

Nice welding altho I would go for lathe in second half of this repair :)

[@enigma9789]

When are you going to make some new videos?

[@blairguinea6811]

Amazing !

[@madcapmagician6018]

you the man brother😁👍

[@vaughngrubesic4932]

Wouldnt just adjusting the balace of the current acheive the same affect as the positive square wave and negative triangle wave?

[@otm646]

It's not the same, It's not just energy under the curve, it's a time rate function for the maximum temperature of the material

[@oceanic8424]

[07/09/21] Very nice repair. Done in 72 mins is quite amazing, and speaks to experience; most would take much longer than that. How many psi air pressure will the housing, and thus the repaired area be exposed to?? Note: Besides Fronius, which other machines have waveform selectability?

[@RecklessRegal]

The repaired area will not see any pressured air, only atmospheric pressure.

[@oleran4569]

@@RecklessRegal Why does it require coating?

[@RecklessRegal]

@@oleran4569 To keep heat in the turbo and thus impeller speed up. It also helps keep under hood temps down.

[@oleran4569]

@@RecklessRegal Thanks!

[@ClumsyCars]

I would have buffed the sharp edges and sent it

[@felderup]

ever done something related to homemade welders?

[@legnanortatem9612]

Are all the tools cost more?

[@andreasanai3542]

Hour price in the USA Is very very high for everything

[@billybaine9943]

What was the camera gear u used to video please

[@madcapmagician6018]

one question how would you re-coat the area where the ceramic coating was removed?

[@RecklessRegal]

They will blast the whole piece to strip all the coating off then coat the entire thing.

[@BruceLee-xp5fc]

Good candidate for a v band

[@RecklessRegal]

No real need for one.

[@es47]

Did therepairhold goodafter reindtalled

[@dennisk8930]

I would have just filed the sharp edges and ran with it.

[@vegas_the_trucker1595]

Question... wouldn't it have been easier to just remove the bulge with a rasp & add as little material as possible since the material was only deformed & not broken or cracked

[@ArcMastersLLC]

Sometimes you got to break the rules to get the job done right.

[@gabewhisen3446]

Where you at dude did the tweakers getcha

[@bigbothoee8617]

Couldn't you just use a er and dolly and heat to iron the damage out ?

[@dont-want-no-wrench]

if it were steel, but aluminum not so good

[@wcmwfab935]

There are few welder like us thats for sure. Most people don't even think about the metallurgy

[@NicolasGirls]

Oh dear.

[@atiaaatiaa56]

Halow mester ithis goud jobe you maike a laike your vedio

[@robertsmall1715]

More than good enough, its not for race application. Better welds than mine.

[@Paulster2]

While I understand you are creating content for your channel, the damage on the inlet would not have affected performance of the turbocharger. It's just a little ugly ... and then, it would be completely covered by the intake tube so it wouldn't be seen at all. Really, this was an unneeded repair.

[@TheFabricatorSeries]

What if the turbo is not covered by an intake.... 🤔

[@Paulster2]

@@TheFabricatorSeries - Then you're doing two things wrong. You're sucking hot air from the engine compartment and you're not filtering the incoming air. Again, it's not pretty, but it's still very functional and won't hurt performance. This is what you call a "function over form" sort of attitude. All-in-all, you did well on the repair. It looks good and the part is functional. Just a dab of spray paint and the job is done :o)

[@masonryan5139]

Dont all youtubers have no hoods and turbos high mounted with maybe a turbo gaurd at best?!

[@RecklessRegal]

@@Paulster2 This turbo sucks only fresh air from outside the engine bay and a filter robs over 200 whp. It will be ceramic coated again, not spray painted.

[@Paulster2]

@@RecklessRegal - Really? I hope you're kidding, right? Ceramic coating along with the weld repairs? Costs more than a replacement part would. Besides, it wasn't ceramic coated in the first place or a wire wheel wouldn't have taken the coating off. And 200hp? You're not serious? Maybe 15hp (and that'd be generous), but not 200. The turbo isn't big enough for anything serious. If someone was using it for some type of racing/street use, they'd be putting a filter on it for the street, and putting a coarse screen on it for race to keep the bigger chunks out. Either way, the part which was damaged would be covered up.