Alumi-weld, JB Weld or a Shim ?

[Mark Osterman]

I am getting ready to install the Master Carburetor in my T and am trying to decide how to fix the aluminum dedicated Master intake manifold. One of the bosses on the manifold is worn / crushed and I’m faced with the choice of building it up with an Alumi-weld rod, JB Weld or using a shim. It’s the difference of 1/8” - 3/16” that needs to be filled to make it the same height as the other boss and that on the exhaust manifold.

[John kuehn]

Could you build up one side of the tab or ear that holds the manifold on? Might be easier to do than building up the manifold. If it’s like the common ones that’s used on T’s you wouldn’t lose much if it didn’t work since it’s a lot more common that your manifold.

[Jerry VanOoteghem]

Could you build up one side of the tab or ear [clamp] that holds the manifold on? Might be easier to do than building up the manifold.

Excellent idea!

[Mark Osterman]

John, That would work and I understand the reasoning but I don’t weld steel and I think that would be the way to go if building up the clamp. But there is another thing. The boss on the aluminum manifold is actually crushed in a little. See the picture below. I think it might be important to fill that void and build up the area in case the metal is thin.

[Scott_Conger]

If it were mine, I would not be applying plastics or alloys to the manifold; I'd be taking it to a welding shop and let them build it up and then dress it back with my mill...and in the absence of a mill, then with a mill file and emery paper

[Mark Osterman]

Scott … sounds like the best idea.

[Wayne Sheldon]

My dad used a fair amount of the open gas aluminum "brazing" technique to "weld" aluminum plates. He was very good at it. One minor (?) objection to it is that the color is more dull gray than shiny. Could be painted over with aluminum spray paint?
I never have tried it, so I can't help with that part of the answers.

Hokey repair J B Weld a piece of aluminum material would work? Maybe? But frankly, for this use I would NOT recommend it for several reasons. Heat, vibration, and general stress among them.
I think J B Weld has its place in repairing and restoring (?) antique automobiles. But not here. (You really should see some Bakelite repairs I have done!!)

For this item? I really think taking it to a real inert gas welding shop that does aluminum repairs and having it built up is the best way to go. I don't know what the cost could be these days? But before all this modern idiocy it wasn't very expensive. A few years ago, a local shop quoted me a "likely $35 minimum weld" for something I was considering having fixed.
Once properly built up, it could be whittled down and shaped nicely by several methods depending upon your tools available and skill levels. Amazing what can be done with nothing more than a hack saw and a good file.

[20touring]

Having worked as a steel welder in my younger days I can tell you the only way to go is with a professional welder that will understand the complexity of the material they are dealing with as well as the rarity of the part. Going “cheap” will only cost more later. The piece of mind is worth the extra $$$ !

[Joe Bell]

Most of this early aluminum welds wonderful, does not have all the extra in it like they do now, I would guess it is thin in those area or it would not have compressed so if you do take it to a welder it may blow through at first then you have some more clean up on the inside.

[Art M]

Take it to a good welding shop.

Nearly 60 years ago I worked in a tool welding shop, where I learned how to stick weld aluminum. Later, the shop used tig to weld aluminum.
Now just stick welding steel is about all I can handle.
Art Mirtes