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blackknight
08-20-2014, 02:22 AM
I don't know if this is the right place, but I'm cutting down the runners on a stock beer barrel intake, I will have to add weld to the low spots and go thru it again with the dremel, and maybe gasket match the head side, again I'm doing this just for Shits and giggles, I'm going to take down the top where the 2bbl holes are to about 1/2" and smooth it out, & i was planning on welding the plate back on instead of making a plate with high temp rtv, any way here are some pics!

http://i176.photobucket.com/albums/w180/99blackknight/20140819_174248.jpg (http://s176.photobucket.com/user/99blackknight/media/20140819_174248.jpg.html)

http://i176.photobucket.com/albums/w180/99blackknight/20140819_174255.jpg (http://s176.photobucket.com/user/99blackknight/media/20140819_174255.jpg.html)

http://i176.photobucket.com/albums/w180/99blackknight/20140819_174449.jpg (http://s176.photobucket.com/user/99blackknight/media/20140819_174449.jpg.html)

stevenz1inoc
08-20-2014, 02:39 AM
Keep in mind that if you are planning on welding a plate onto the manifold you are going to most likely need 6061 plate and the problem there is that you are going to be welding it onto a piece of aluminum that is cast, and I'm not exactly sure they cast them out of 6061 but who knows. The reason I bring this up is because that plate gets hot, pretty damn hot actually. And 6061 aluminum plate welded onto cast aluminum might have some issues. You have to keep in mind the dilution factor of your welding rod which will probably be 4043, combined with the 6061 and the cast metal. There could be some serious cracking issues if not done absolutely perfect and even then you might see issues.

What ever you do, don't use 5356. It is prone to cracking when used where service temps above 152 degrees are seen on a regular basis.

In fact I would read this: http://www.millerwelds.com/resources/communities/mboard/showthread.php?20663-Tig-rod-4043-or-5356

stevenz1inoc
08-20-2014, 02:42 AM
It's funny, I just read that post I linked and they had the same info about the 5356 cracking above 150 degrees.

Friggin' R/T
08-20-2014, 02:51 AM
Also you need a gasket if you don't weld it. I learned the hard way the oil eats the rtv away leaving you with no seal.

blackknight
08-20-2014, 02:59 AM
6061-T6 is usually welded with 5356 at our job, which are usually just panel corners due to the strength, I do understand going from regular aluminum to cast aluminum and it is a bitch, I'm just curious and I'm open to the info, again just a play piece

ScojoDak
08-20-2014, 03:03 AM
6061-T6 is usually welded with 5356 at our job

Do you think pre-heating the kegger prior to welding will help?

blackknight
08-20-2014, 03:05 AM
That would be alot of heat but a possibility, I can throw it in a batch oven preheat it to 450 all ready to go then weld as soon as it comes out

stevenz1inoc
08-20-2014, 04:07 AM
6061-T6 is usually welded with 5356 at our job, which are usually just panel corners due to the strength, I do understand going from regular aluminum to cast aluminum and it is a bitch, I'm just curious and I'm open to the info, again just a play piece

Well if you want to risk using 5356 that would be your choice but It will crack at temps over 152 degrees. It's science based on the composition of the filler. Save yourself the trouble and worry and just use 4043.

stevenz1inoc
08-20-2014, 04:12 AM
Do you think pre-heating the kegger prior to welding will help?

Pre-heat would be tough unless you had a thermal blanket to help keep the heat in. I'd skip the pre-heat, bevel the joint crank up the amps to about 225, and weld it. But don't forget to remove the oxide coating before each pass. You can turn down your cleaning and improve the penetration. Could also use a 5% helium mixture to improve the penetration.

blackknight
08-20-2014, 04:15 AM
This would be a trial and error kind of thing, I don't want to put time into porting it, if you will, if I'm going to trash it while welding! Again I'm not going to use it since I already have and m1-4bbl,

stevenz1inoc
08-20-2014, 04:22 AM
This would be a trial and error kind of thing, I don't want to put time into porting it, if you will, if I'm going to trash it while welding! Again I'm not going to use it since I already have and m1-4bbl,

its a fun little test then.

ScojoDak
08-20-2014, 04:36 AM
This would be a trial and error kind of thing

Good luck. Let us know how it goes for future reference.

blackknight
08-20-2014, 08:27 PM
I'm going to finish cleaning it out, then attempt the plate welded on with 4043, I'm also contemplating on the idea of cutting the 2bbl top, and adding a 4bbl aluminum plate, incase one wants to use a 4bbl zex perimeter plate and choke it down with a 2bbl plate up top, suggestions? Ideas?

blackknight
08-28-2014, 02:19 AM
Update pics, I filled in the low spots and cleaned it a bit, still needs a bit of porting, & gasket matching, I also cut down the center divider down to about a 1/2",

http://i176.photobucket.com/albums/w180/99blackknight/20140827_190012.jpg (http://s176.photobucket.com/user/99blackknight/media/20140827_190012.jpg.html)

http://i176.photobucket.com/albums/w180/99blackknight/20140827_185015.jpg (http://s176.photobucket.com/user/99blackknight/media/20140827_185015.jpg.html)

http://i176.photobucket.com/albums/w180/99blackknight/20140827_185001.jpg (http://s176.photobucket.com/user/99blackknight/media/20140827_185001.jpg.html)

http://i176.photobucket.com/albums/w180/99blackknight/20140827_184949.jpg (http://s176.photobucket.com/user/99blackknight/media/20140827_184949.jpg.html)

ScojoDak
08-28-2014, 03:25 AM
Git-R-Done.

blackknight
08-28-2014, 04:01 AM
On that theory of cutting out the 2 holes and adding a 4bbl center is out of the question, not enough room I would be cutting into the runners, now time to order that variable speed die grinder and get it cleaned up, aluminum plate back on and powder coate it!

blackknight
09-09-2014, 02:59 AM
A little update I finally got the right die grinder for a good porting job, I thought I ordered a variable speed one but this is what showed up! http://i176.photobucket.com/albums/w180/99blackknight/20140908_144828.jpg (http://s176.photobucket.com/user/99blackknight/media/20140908_144828.jpg.html)

Motorhead
09-09-2014, 06:39 AM
A little update I finally got the right die grinder for a good porting job, I thought I ordered a variable speed one but this is what showed up! http://i176.photobucket.com/albums/w180/99blackknight/20140908_144828.jpg (http://s176.photobucket.com/user/99blackknight/media/20140908_144828.jpg.html)

Nice......but we don't want to see the box.
Quit teasing us and lets see pics of the tool and the tool being used.:biggthumpup:

blackknight
09-09-2014, 03:54 PM
:biggthumpup: I'll try to get to it today!

blackknight
09-16-2014, 04:01 AM
A little update, I think I need to order some better cutting wheels any recommendations?
http://i176.photobucket.com/albums/w180/99blackknight/Mobile%20Uploads/20140915_185304.jpg (http://s176.photobucket.com/user/99blackknight/media/Mobile%20Uploads/20140915_185304.jpg.html)

http://i176.photobucket.com/albums/w180/99blackknight/Mobile%20Uploads/20140915_185258.jpg (http://s176.photobucket.com/user/99blackknight/media/Mobile%20Uploads/20140915_185258.jpg.html)