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Hi, just wondered if anyone has had welding repairs undertaken successfully to a magnesium alloy rocker cover? I have damaged one that my local `welding specialist `has tried to mend, but just made a botch of it. He obviously dosnt have correct gear/weld rod/skills.
Or maybe I`m being harsh and it just can`t be welded??
Any advice welcomed. Cheers, Swampy.

I know it's a bit of a bodge but chemical metal may be your friend here if you clean it off well brake & clutch cleaner works and if you take your time you should be able to get a good finish
i do a couple of days a week in a local garage and we have used it on more than one merc rocker cover [get one with black death that has sealed it's self and the puller will punch through the rocker cover]

if you manage to weld it you will have to fill and spray it to look pretty so give the chemical metal a go

Others will probably have better idea's

Hope this helps dai

Hello Dai, thanks for your quick reply and info.
I had considered Chemical Metal, however I had (have) a hairline crack that leaked oil rather than a hole as such. I was worried about putting any on the inside, as it would just be a `butter-up` excercise, in case it came off in time and spun around in amongst my valve gear.
Thought that if it was welded inside and buffed filled and painted outside it might have worked . What I have now is a weld inside and out -which has also cracked as it cooled so will also leak (possible wrong welding technique or filler rod??). So now I`m no further forward really. Just don`t know if Magnesium can be welded succesfully.
Might come down to a bit of grinding out a V on the crack line and filling externally only with CM before finishing. (Now`t is ever simple in my world!). Cheers, Swampy.

Try this. http://www.magnesium-elektron.com/about ... m.asp?id=3 There is a link to PDF that has a lot more useful information but quite technical but does give correct welding rod specification and advice on temperatures etc.

Swampy wrote:. So now I`m no further forward really. Just don`t know if Magnesium can be welded succesfully.
Might come down to a bit of grinding out a V on the crack line and filling externally only with CM before finishing. (Now`t is ever simple in my world!). Cheers, Swampy.

I'm sure there are plenty who can answer but I wouldn't recommend grinding magnesium as the dust and shavings can burn at high temperatures.
Google has all the answers

http://www.practicalmachinist.com/vb/ge ... gs-145819/

http://www.weldingtipsandtricks.com/wel ... esium.html

nab 301 wrote:

Swampy wrote:. So now I`m no further forward really. Just don`t know if Magnesium can be welded succesfully.
Might come down to a bit of grinding out a V on the crack line and filling externally only with CM before finishing. (Now`t is ever simple in my world!). Cheers, Swampy.

I'm sure there are plenty who can answer but I wouldn't recommend grinding magnesium as the dust and shavings can burn at high temperatures.
Google has all the answers

http://www.practicalmachinist.com/vb/ge ... gs-145819/

http://www.weldingtipsandtricks.com/wel ... esium.html

You just took me back 45 years i remember that from school!

Thanks for your info guys, much appreciated.

You are right- (I nearly forgot)- `Google is my friend`.
Now think decent TIG welding, with correct rod material (as now advised), is the best way forward. Don`t think it will be oil/gas tight otherwise. (It was only a hairline crack to start with, but that leaked oil. The repair weld(if you can call it that) does not even pass the water leak test.

Now to find someone local with the gear and interest to do it properly and make a job of it . Let you know how I go. Cheers, Swampy

Why not contact Steve Turner? (MrT4Turbo)

There's a clue in his address

Steve Turner T/A TPCS
www.tpcs-magnesium-refurbs.co.uk
email; tpcs2010@live.com
TPCS
Unit 4b Broadlane Farm
Sells Green
Melksham
Wiltshire
SN12 6RJ
Tel; 01380-828561
Mob; 07840628300


Since its Mag Alloy, and not Gold, Lead or Uranium - postage should be cheap?

Al

Nigel, - meant to say, you too appear to be a collector, --Vfr, R1100s( mandarin)SLR 650 and a Dullville. I`m working on it ,with somwhat similar T595 Trumpet, R1200S (shine yellow) and KTM Duke 2.
Never fancied a dullville however, - next purchase may be a Ducati (just because I`ve never had one), although I fully expect reliability probs! Only neeed to find the Wonga now and next winter`s project may become a reality. Cheers, Swampy.

Thanks Blackal,
I have just send them an email enquiry to see if they can help on this. Await response. Cheers, Swampy,

Swampy wrote:Nigel, - meant to say, you too appear to be a collector, --Vfr, R1100s( mandarin)SLR 650 and a Dullville. Cheers, Swampy.

Not really a collector , just too lazy to sell ,( although I've just managed to sell my SLR) the Deauville is more of a recession buster for long haul trips .