Thanks guys. Putting a bolt in as a plug was actually my first thought, but
the manifold is only about 3/16" thick at that point and I am afraid that
won't leave enough meat for the bolt to fully grab. However, I just did a
little playing around with my earlier test and am now confident that,
consistent with what Scott just reported, the aluminum rod does seem to have
bonded with the base metal. I took a nail just a hair smaller than the
diameter of the original hole and tried to hammer the plug out; the nail bent
but the plug didn't budge. I drilled a second hole and tried again and this
one worked just as well. I wouldn't trust a bracket brazed in this manor, but
am now confident that this is a good way to plug a small hole.
Sent from my iPad
On Jan 16, 2011, at 3:35 AM, "scottmryan@netzero.net" <scottmryan@netzero.net>
wrote:
> The MAAP gas torch is probably hot enough; I would preheat the manifold to
> around 500 degrees F or so, then it should bond. (The 'soft' flame on a
acet
> torch is probably a little cooler, but likely it's suggested to prevent
> oxidizing the aluminum.)
> I have done aluminum brazing several times (once using propane on a very
small
> repair), although it's been 15 years? since I last did it. One time was
using
> some rods from my grandfather, and another time was something I picked up
at
> the local welding supply shop. All of the repairs I did held up well-one
was
> for a CV carb bracket/housing for a 83 honda prelude. I did paint all the
> repairs since I was not sure if corrosion would compromise the repair.
>
> Good luck! Scott R
> PS: I think tapping the hole for a aluminum bolt, sizing it for length, and
> beveling the underside of the bolt head (and a matching bezel in the hole),
> gluing it in w/ jb weld, and grinding it flush would also work well.
> ---------- Original Message ----------
> From: Jim Stone <jandkstone99@msn.com>
>
>
> I need to fill in a 1/8" hole in an aluminum intake manifold prior to
having
> it powder coated.
> <snip>
> Right now, the hottest torch I have is an old MAAP Gas one that has served
me
> well with small projects for many years, mostly plumbing.
>
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