Paul,

 Got the headers back from the welder and they look pretty good.

 The intake hardware had issues

 He did not weld the injector holder to the 2" tube because the sample
 weld that he ran just melted.

 He said he needed a water cooled tig torch

 The point where the injector holder contacts the tube at an acute angle
 does not permit him adequate access

 Should this piec use JB weld for sealing and tack welds to hold it
 secure?

 Was wondering what your experience was.

 Thanks for any help

 Joe Berki
 Limo EZ


 I have a couple more if you can find a better welder :)
 Aluminum is not easy to weld.

 You can glue them on with epoxy if you treat the aluminum
 first.

 Paul Lamar


 Donnknow if a water cooled tig torch is the answer. The water cools the
 torch, not the weld. Aluminum is difficult to weld because it tends to
 melt away from you if you don't have the knowledge and experience to
 weld it. It seems as if your welder was welding the aluminum as if it
 were steel.

 Get a different welder or perish the thought-- have a professional do
 it. In my intake manifold, I welded what I could, but will use JB in the
 acute angles and where I couldn't get my torch.

 Rich



I gave the welder a sample of the tube that I wanted the injector holder
welded to.

I believe if i went with a thinner wall it would be a non-issue.

What wall thickness would you recommend for the injector holder tubes?

Joe


For welding injector holders a thicker tube is easier.  I had lots of welding
experience on steel and mig alum, then had to teach myself tig at age 56.
Welding .049 is fairly easy, .035 harder unless to other thin parts.  For thick
parts too thin the thick part needs lots of heat, and if the weld zone gets too
close to the thin, there is a big hole right quick!  Torch angle is very
important.  2024 and 7075 alloys are considered not weldable.

Dan F