djsy934
Active member
I have done this mod before with weld, after struggling with bad castings and warping I will no longer attempt welding them. This is what I have come up with as a re-placement. It is not 100% perfect but as close as we can get, there is no way of matching a cast aluminum color to billet aluminum, there will always be a color difference. Price will stay the same $250 with your good core. This is how the process is done:
Machine blind pocket in Plenum with under-cut pockets for epoxy:
Machine exact fit insert with under-cut pockets for epoxy:
Press fit with JB Weld (the epoxy ended up not as thick as the pictures, this was the initial application)
Press fit and clamped for 24 hours:
Machined flush and engraved:
Glass bead blasted to remove cutter marks and for paint:
Painted, machined over spray off and grained with 220 paper to remove cutter marks and blend dis-similar aluminum's:
Machine blind pocket in Plenum with under-cut pockets for epoxy:
Machine exact fit insert with under-cut pockets for epoxy:
Press fit with JB Weld (the epoxy ended up not as thick as the pictures, this was the initial application)
Press fit and clamped for 24 hours:
Machined flush and engraved:
Glass bead blasted to remove cutter marks and for paint:
Painted, machined over spray off and grained with 220 paper to remove cutter marks and blend dis-similar aluminum's:
![Quickstop [UK]](/data/avatars/m/5/5165.jpg?1570199786){kind=avatar}
