NCchris Posted January 25, 2007 Share Posted January 25, 2007 I have a N42 intake and want to "clean" it up. On another thread, it was suggested to plug the holes with a tapered threaded plug. Some of those holes could be easily tig welded shut then ground flush on both sides. Anyone have any experience welding this casting? TIA chris Quote Link to comment Share on other sites More sharing options...
Warren Posted January 25, 2007 Share Posted January 25, 2007 Clean it real well, any place that is to be welded should be ground clean and bolt holes that you plan on filling should be drilled until you get to clean fresh material. It welds very well, but requires ALOT of heat, i.e. stay away from the flanged areas unless you plan on machining them flat again. Don't forget to Jet Hot coat it once you're done. It'll look AMAZING. After welding, Sanding, Polishing & Before Jet Hot Coating After Jet Hot Coating Quote Link to comment Share on other sites More sharing options...
Challenger Posted January 25, 2007 Share Posted January 25, 2007 Did you polish the entire manifold, what did you start with to make it smooth? Other then all the egr tubes and valves what all can you take off the intake. Quote Link to comment Share on other sites More sharing options...
Warren Posted January 26, 2007 Share Posted January 26, 2007 Believe it or not, a belt sander and a dremel tool...sanding it with a belt sander makes it easy to get flat surfaces. The dremel tool comes in handy between the runners where the belt sander can't get. Quote Link to comment Share on other sites More sharing options...
240hoke Posted January 26, 2007 Share Posted January 26, 2007 Welding the holes shut it really doesnt matter as most that you will want ot plug will not be through holes. The through hole should probably be saved for vaccum sorces unless you plan one doing somehting custom. That being said I had do trouble welding up the holes in my intakeI just used some 4043 rod, make sure everything is nice and clean though. and smooth out the casting a bit. Quote Link to comment Share on other sites More sharing options...
vashonz Posted January 26, 2007 Share Posted January 26, 2007 Running one pass without adding filler can help to clean up the cast aluminum, then wire brush it, and do a pass with filler. Quote Link to comment Share on other sites More sharing options...
Roostmonkey Posted January 27, 2007 Share Posted January 27, 2007 I shaved most the openings off the top of this manifold and tig welded it up.ThenI drilled/tapped some of the mounting holes on the side of the manifold for vacuum ports/boost guage ect... This keeps the top clean and uncluttered. Then it was powdercoated with a hammered siver finish. If you dont have a nice clean nonporous weld, youll get some outgassing during the PC and will leave blemishes in the paint. Quote Link to comment Share on other sites More sharing options...
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