Can you weld a cast aluminum intake?
I just got a PD150 intake for my AAZ and it has a lot of fittings and opennings that I'd like to weld shut so I can smooth and polish it.
You can with the right equipment. You can TIG cast aluminum, quickest and easiest way. You can MIG it as well, but you need aluminum wire of course, and typically a spool gun to feed it, and usually pure Argon shielding gas.
Actually, you can even braze it which would probably be the easiest, if you were just filling holes brazing would probably be the best. If you don't have the gear to do it, any welding shop should be able to do that in just a few minutes.
Brendan
you can also cheat by tapping and using bungs
you can also cheat by tapping and using bungs
I'm gonna polish it, so bungs would be very obvious.
If you have a stick welder, you can go that route too. You'll need to get the intake re heat treated to relieve the stresses made in the metal from welding.
You can get the egr delete pipe from TDIPARTS.com, this will go straight into a coupling for your intercooler
advise what parts you need and what size and I will get the silicone stuff at cost from the mfg
email me pr a pdf file of a list of products
You will just have to get the I.C. and hard tubes /45/90
Tubing with elbows will be less than silicone elbows
Color choices black , red , blue..
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just clean it very well (aluminum is porous and holds lots of oil) and weld it with a mig gun if you dont have access to a tig welder. be sure to weld pretty slow and pretty hot so it can burn the impurities out of the metal. cast metal is much harder to weld than sheet, unless the cast is brand new.
