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


-

With flux, you can gas weld Al. Darn tricky though as it wants to drop away.
It can also be welded with a Mig, but it will not necessarily be pretty. The
Tig is the way to go. Water cooled torch is just for high duty cycles, or high
power for thick materials. Not the case here. Welding two pieces of different
thickness is tricky even with ferrous metals. You have to weld more on the
thick part or you burn through the thin material. If you go to thinner tubing
you will make the problem worse. You need a welder that knows his manure! The
machine setup is different than for steel. And if I remember right the gas is
different also. You should be able to weld it with a small Tig machine, even
the 110V units. A 220V power supply would be better. A "hobbyist" size is more
than enough for this job.

Dale Davies