Rear end welding question

jwalsh965 · 11-01-2014, 07:12 PM

I am wondering can you weld the rear end gear case on a 2004 gas club car DS. I was told you cant weld these rear ends because there cast aluminum is this true.

Swan · 11-02-2014, 09:34 AM

cast alum can be welded but its takes a skilled welder (not me lol) and it needs to be super clean for it is porous and traps oils .

jwalsh965 · 11-02-2014, 11:13 AM

Thanks Swan, I figured that, just trying to confirm.

DOOmsman · 11-02-2014, 04:12 PM

Inquire some racers, they weld up windowed engine blocks all
the time.

CharleyL · 12-13-2014, 01:37 PM

You will need to find somebody who has a TIG welder and experience welding cast aluminum. He won't be very cheap because it may require welding 3 times and grinding out the first 2 times to get the oil and grease burned out of it enough to get an acceptable weld. You can clean the outside, but the pores hold the dirt until it gets hot. A motorcycle shop may be able to recommend someone.

Charley

compmikey · 05-10-2015, 08:50 AM

welding AL is tricky compared to steel. Especially cast AL which has a narrow heat range between "workable" and "yikes! this stuff is flowing away butter in a microwave oven".
Although I'm questioning exactly why you need to static connect to the cast AL, and can't use brackets of some sort, IF you do need to weld something there, heat the part and use a a MIG with argon gas. I say this as the owner of a large miller TIG who has not yet been able to weld any cast aloonium with acceptable results. :-)
One last thought. It CAN be done. Drag car guys weld up both billet and cast aluminum heads to fill chamber-to-chamber slots after head gasket failures fairly often.

raydhd · 05-10-2015, 03:33 PM

Harley engine cases and atv transaxles so local harley dealer or atv shop probably knows the goto al welder in your area.

jwalsh965 · 05-10-2015, 04:17 PM

Thanks guy's for all your suggestions, I ended up buying a used rear end case.

kab69440 · 05-11-2015, 03:22 AM

Welding anything formed by sand casting sucks. The worst is potmetal.

compmikey · 05-12-2015, 06:19 AM

Pot metal rhymes with JB-Weld in my world. 8-)

11-01-2014, 07:12 PM	#1
jwalsh965 Getting Wild Join Date: Jan 2013 Location: st. john's nl canada Posts: 139	Rear end welding question I am wondering can you weld the rear end gear case on a 2004 gas club car DS. I was told you cant weld these rear ends because there cast aluminum is this true. Last edited by jwalsh965; 11-01-2014 at 07:37 PM.. Reason: DELETE

11-02-2014, 09:34 AM	#2
Swan Cave Dweller Join Date: Apr 2013 Location: Always On The Move Posts: 22,229	Re: Rear end welding question cast alum can be welded but its takes a skilled welder (not me lol) and it needs to be super clean for it is porous and traps oils .

11-02-2014, 11:13 AM	#3
jwalsh965 Getting Wild Join Date: Jan 2013 Location: st. john's nl canada Posts: 139	Re: Rear end welding question Thanks Swan, I figured that, just trying to confirm.

11-02-2014, 04:12 PM	#4
DOOmsman Gone Wild Join Date: Jul 2008 Location: Reddick IL Posts: 11,220	Re: Rear end welding question Inquire some racers, they weld up windowed engine blocks all the time.

12-13-2014, 01:37 PM	#5
CharleyL Gone Wild Join Date: Dec 2012 Location: Central North Carolina Posts: 527	Re: Rear end welding question You will need to find somebody who has a TIG welder and experience welding cast aluminum. He won't be very cheap because it may require welding 3 times and grinding out the first 2 times to get the oil and grease burned out of it enough to get an acceptable weld. You can clean the outside, but the pores hold the dirt until it gets hot. A motorcycle shop may be able to recommend someone. Charley

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05-10-2015, 08:50 AM	#6
compmikey Getting Wild Join Date: May 2015 Location: NE Ohio Posts: 124	Re: Rear end welding question welding AL is tricky compared to steel. Especially cast AL which has a narrow heat range between "workable" and "yikes! this stuff is flowing away butter in a microwave oven". Although I'm questioning exactly why you need to static connect to the cast AL, and can't use brackets of some sort, IF you do need to weld something there, heat the part and use a a MIG with argon gas. I say this as the owner of a large miller TIG who has not yet been able to weld any cast aloonium with acceptable results. :-) One last thought. It CAN be done. Drag car guys weld up both billet and cast aluminum heads to fill chamber-to-chamber slots after head gasket failures fairly often.

05-10-2015, 03:33 PM	#7
raydhd VC 460 CLONE GONE WILD Join Date: Oct 2014 Location: Ray BY The Bay NJ Posts: 10,639	Re: Rear end welding question Harley engine cases and atv transaxles so local harley dealer or atv shop probably knows the goto al welder in your area.

05-10-2015, 04:17 PM	#8
jwalsh965 Getting Wild Join Date: Jan 2013 Location: st. john's nl canada Posts: 139	Re: Rear end welding question Thanks guy's for all your suggestions, I ended up buying a used rear end case.

05-11-2015, 03:22 AM	#9
kab69440 Gone Wild Join Date: Aug 2010 Location: Marion, Ohio Posts: 1,391	Re: Rear end welding question Welding anything formed by sand casting sucks. The worst is potmetal.

05-12-2015, 06:19 AM	#10
compmikey Getting Wild Join Date: May 2015 Location: NE Ohio Posts: 124	Re: Rear end welding question Pot metal rhymes with JB-Weld in my world. 8-)

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