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nice work! those things can be a bear. a dirty, oily bear.

I do a lot of cast aluminum repair work and I found that for small tabs like that it is best to just use the little part that is broken as a reference. I use 4043 filler and just buildit back up piling weld on top of weld until I have the right amount of metal added to the main piece.after that I'll use a body file on the machine surface and the gasket to Mark where the hole needs to be. Then with a Dremel or a die grinder shape the little tab and drill the hole. I found it to be way faster and easier than trying to weld a piece of cast aluminum that is small especially if it is a shity quality.

This is the type of welding video I like. No jabbering on and on about trivial or obvious things. No going off on tangents. Showing the “face” of the work most of the time and not the face of the speaker. Letting us get a good look at the finished weld. Well done.

As a fairly new tig welder myself, when I struck that first arc I spent more time re-grinding electrode points than I did attempting to weld. I would highly recommend The Fabrication Series videos for ANYONE who has the ability to pay attention to detail and follow instruction. I have learned more by watching several hours of his videos than I could ever have just reading online forums. One thing that you can't teach is physical control, but the pointers and suggestions sure have made a massive difference in my weld quality. Thank you for all your great information sir. 😎👍

I have been welding cast Alu for 6 years now and around here nobody wants to do it. I am so glad to see you have the same struggles as me!!!! Its rarely beautiful but Ive had only 2 comebacks in 6 years. I always thought the PRO’S would be doing a much better job. I have another technique as well. Like when Im welding on diesel soaked parts have the part sit in Acetone bath for a while, then heat it with a propane torch. A lot of bad stuff seems to come out. Wash it off and brush it off. I do this several times. Seems to help a lot. But basically the way you do it is how I’ve been doing it for 6 years. Thanks for at least showing me I haven’t been doing it wrong all this time. Love your channel keep up the good work.

I always enjoy the explanations that you give. The reality of what it takes as well as frustrations like dipping the tungsten. I always look forward to your video's

Your videos are absolutely classroom excellent. You keep to the point, excellent commentary and justify everything and what needs to be accomplished through every step. You explain the entire process very, very well. Thank you.

You’ve got a real honest and genuine attitude. Thanks for sharing your knowledge. I’m a beginner and I appreciate it Man

Good work Justin, That is the reality of welding up Alluminium Castings. I do one, now and then, and sometimes they take quite a bit of work to get that crap out, to make a solid weld, but that is the nature of the beast.

I love this man you these "little" repair are great for us welders. I'm mobile and I'm welding cast aluminum tomorrow and found this video trying to freshen up my memory as it's been a long time since I last did cast

for years i thought it was my fault in welding cast alluminium parts, then I understood it was an alluminium quality issue.... It's relieving to see you have the same problems....

Ha! Thanks for making this video, and talking about the quality of the metal being a factor in how much trouble you can have. I was welding a 1/8" adapter into a cast water neck and had to go back over, and over again to fill the pinholes. At my level of expertise I thought I must have missed something in your class, and thought I was doing something wrong.

Thank you so much for this video! I’m doing a 240sx water inlet tube in aluminum and it drove me crazy!! Finally I can understand why it won’t do perfectly dimes. Tried changing everything looking for that perfect weld!!

I’m self taught so far any cast I’ve welded hasn’t been to bad but I’ve learnt so much from your videos

I'm nowhere near the level of skill that you are, but I'm glad to see that the annoyances I deal with when working with nasty old cast aluminum are universal and not just me totally sucking at it. I can make strong welds on parts like this, but they're rarely beautiful. Thanks for the tutorial, as always!

Thank you for this video. I watch your videos all the time. They are always informative. I've been doing alot more cast aluminum lately. Glad to know it's not just me!

Your craftsmanship is on point. Thanks for sharing!

Thanks for the tips. I’m new to tig and struggling but I won’t give up. Keep up the good work!

Nice, I'm a beginner so every bit of coaching and guidance helps. Much appreciated......

mic from mexico very good video i am learning to weld with tig and sometimes i have these repairs it s good to find someone who does it professionally and learn from you guys thank you

Great video! Tried to repair a part on a RV awning support, it ate my lunch and dinner too! Finally got it to stick, but nothing to be proud of!

Well done, excellent final result.

Thanks Justin , always enjoy your videos. they are so informative.

I love the video, everyone should patiently prep the area like that for a perfect repair.

All made sense to me, great teacher.

Came out looking excellent.

Excellent, I’ve got a 2 stroke casing that I damaged and it will need this kind of repair. Not gonna do it myself but it’s made me wanna go to a tig course at college now after watching

Just love seeing repair job like this ,thank you

Great info for someone learning aluminum Tig in school now enjoy the channel 👍

Cool, thanks for showing us the actual bad with the good. It came out good of course but the steps along the way are helpful!👍

Definitely taught me something I was unsure what welder even gets used good vid man subbed

Nicely done! It took me a while to understand what you meant by 'hammereing down'.

nice work , these jobs can be tricky , a great view even when the welding took priority .

Looks really good! Well done!

Really nice work so your using the tig torch as a cleaning tool and a heating tool to heat the cast aluminum I like it I love this dude he's very knowledgeable

Useful information. Thank you

Someone must really like this old ford manifold

Thank you sooo much... I am a newbie and needed this helpful commentary to motivate me to weld my part on my car....

Aluminium welding is a fun thing to do. I get a lot of car parts that need to be fixed. Some aluminium rims I fixed too. Cleaning is the most important part for sure.

As someone who's never touched a tig torch in my life, I find all your videos fascinating. I'm definitely going to have to buy a tig welder at some point, maybe get a big pile of scrap metal to play with.. Thanks very much for the great info and footage, much appreciated ;)

Rémi Talneau we use a flux capacitor infuser with a diolithic setting. We also use non warp sticks ( NWS) that helps stop warpage. At times we may put the broken part in a parabolic chamber before we pre heat .The chamber realigns the molecular strifacites in the metal. But when were lazy we just weld it

Thanks been doing it for years you can always learn something new

My latest project will be stripped down to just the alloy fram a Honda VFR750f .it was dropped on the left side and as I removed the left footpeg bracket the lower mount broke off Will be reattached once its stripped It was going to be a simple rebuild, now waiting for warmer weather love watching your work

Super insightful. Thanks for putting this vid together!

Nice to see a real pro in action!

We do repairs on the engine cooling fins and we build up a whole fin from scratch, to make sure it is good and clear of impurities due to the age and the part and some times it means we have to build up 5 centimetres worth of ally about 2 mm thick.

Good video, need to repair the mud guard bracket on my gixxer forks, had a go the other day and it melted into a blob! Will try playing with the balance and frequency next time. My biggest problem was trying to keep it clamped together, never even thought of using some flat bar to clamp it together, sure that'll work a treat!

You could have just added the metal and drilled/shaped it, I get it. BUT you showed that even a small piece can be welded back on and "CAN" be done using a technique that works for a bigger piece... so VERY helpful. And thanks for the burr toolset recommendation.

I'm not a welder, but my eye's were welded to the screen for the full video, thank you.

Nice job! I've repaired big oil pans and small engine walls, I wish I had a fancy tig to work with 🤣 was about a year ago and no comeback so I guess its holding up 😎

Excellent repair video and learned a lot.

Thanks for sharing your knowledge. Love the video.

Love ur videos. Keep up the GREAT work.

Great job

Jobs like this with a small tab missing, after a thorough grind clean up, I usually build up all new material, grind it back to a rough shape similar to what was there, file the gasket surface back flat, and re-drill the hole using the gasket as a template. To each his own. There is more than one way to skin a cat. Different strokes for different folks. KEEP UP THE GREAT VIDEOS BROTHER!!!

Nice repair !

I have no knowledge of welding, but your way to comment your work made me look the whole video, well done :)

Its crazy o wish I had these videos when I started welding cast it was manly trial and error but this is basically the same procedure I use good job looks good.

Welded my first little cast iron piece that someone tries super gluing back together... What an absolute pain in the stuff... Hopefully the next one will go smoother.

Thanks mate for another great video 👍

Really good explanation should be a big help. Thanks

Excellent informative video...thankyou for downloading.

Thank you for viding that, I learned a lot and it even gave me an important idea for the future.

This is the right way to weld cast alu good job

Very nice. It help me. Thank you. From Mozambique

Awesome stuff!

Good repair man! I just did a cast aluminum clutch for a motorcycle. I used the Maxal 4943 wets out great like 4043 but stronger.

Great video.

muito bom amigo!!!!! parabens

Awesome homie ! I subscribed bro keep making video's cause i need as much badass maestros as i can get

Awsome info, thank you for your time😀👍

Thankyou for the videos.

Totally makes sense! Wish I had these types of welding machines. Just cracked my thermostat housing and a new one is no where to be found. Probably gonna just weld a mild steel replica

Prep.prep. Prep. Can't say it enough. Preheat. 5000 series filler FGW. (my preference).carbon scratch test. Reducing flame. My procedure, for what it's worth. Thanks for the vid man.

Good work 🦾

thanks for sharing, great video.

nice video and a good explanation ,keep up the good work!!! regards from the Netherlands

Great Video... Thanks for Sharing

I know this an older video, but really funny when you say, "we're not making decorations, just solid repair." Made me laugh, but totally true!

Great video! Thanks brother

I've never welded cast aluminum and I hope I never do after seeing this. Great work 🤘🏻

Great job , good skills ......

Thanks for sharing this with us 👍👌💯

Great video ! Mabey I'll try my hand at it one day soon

Brother I love watching you, learning so much and very appreciative of the time and effort of what it takes to do this, the only down side is I can't hear you, I don't know what it takes to make these so I'm ignorant, but ever vid I watch no problem, your I have wide open and still can't hear you good, just wanted to let you know for those of use that watch on our phones, thanks and God bless

Excellent job. That video took a lot of work to produce.

I need a lawn boy mower deck repaired. After seeing these videos I'm confident it can be done!

Its funny I was a Chevrolet auto mechanic my whole life and I know the value of that part. If you can show me how to fix that then you are my hero. I see you are wearing safety mechanics gloves. A better name for them would have been genius gloves because of all the money you can make with them.

AMAZING STUFF! everyone in my town says this is impossible

Great video thanks

i love this dude

Thank you man. Told me everything I needed to know about cast aluminum. Is it not advisable prepare a cast aluminum wheel?

Very good video. Would brazing or silver soldering be an acceptable repair for that ?

Great video. I don't even have a welder yet, but was wondering what equipment would be needed to do it.

Great video. Can you please make a video on Tig weld repairing a crack in a Magnesium casting such as a rear wheel hub on a motorcycle.

I’ve always liked your work but never subscribed for some reason. I guess I always forgot to. That just changed. Great tips!

your presentation is like listening to the traffic copter guy - take a breath once in a while

Some good skills. Looks easy but doing it, is a different thing.

great info, flathead ford v8's had aluminum intakes, single 2 barrel, I'm setting up to cast parts to convert them to 3x2, i have a friend with 50 or more stock intakes, welding onto the old intakes will be a challenge, I have welded cast before, sometimes it welds beautiful, other times it is more of a mechanical bond, who know what 1940's aluminum has in it.