Welded Corner Casting

I found a crack in the right front corner casting. The boat is a 75', a $500 learning investment, and most components are really tired. All things considered, I decided to try heliarcing to deal with the problem. Many are of the opinion this is a mistake. Took it out today, and it dealt several hours with 15-20kts with no sign of recurring crack. Time will tell. Anyone with first hand experience in this area? I'll keep you posted on the long term results of the repair experiment....

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Mims, FL

You should be OK, but check e bay you will find used ones cheap there.

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Bodhisatfa

Update: I've been sailing a half dozen times since the weld job (10-12kts typically, once 20kts) and the weld is holding together nicely.

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Mims, FL

Further update: sailed on the weld a dozen times or so since last update, once in gusts to thirty knots in three foot seas. A rudder snapped off, but the weld is holding up just fine.

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Mims, FL

I have a crack in my corner casting and wonder how you welded yours.
What type of wire/gas/amperage did you use and how did you prepare the crack prior to welding? I have a Lincoln 140 and thought I would try a weld but before I do I thought I'd see how you approached it as my welding experience is 99percent steel. Thanks

Guess I am a bad reader,,re read your post and saw you heli arc welded it. You are talking TIG. I dont have a TIG welder. Wonder if a MIG could do a decent job?

I have a clear anodized (silver) right front corner casting in excellent shape...no corrosion (no salt water), no cracks, holes aren't oversized, rivet holes are NOT overdrilled, little use. $40 total including shipping... calebsboge (at) hotmail.com

Aluminum welding virtually requires TIG, even though Lincoln says you can do it with one of their MIG units.

They neglect to tell you that the machine needs to be thoroughly cleaned and the feed line changed to one used for aluminum wire only. Al welds are highly sensitive to contamination, especially with steel.

I kinda think most aluminum welding is actually MIG, TIG is too slow and therefore expensive. Good for showy work though. Anyway, I will give it a go and see. I was wondering what prep work was done, was a vee ground or did he just TIG the crack. Penetration is my concern. It'll probably be ok. Let you know. Thanks.

Ya, prep was key, and I might add difficult. As the other post commented, to do it right, there has to be no corrosion... it has to be very clean. The shop that did it used brake cleaner to try and get the area as clean as possible. They first used a grinder to V out the crack, then cleaned it thoroughly, filled in space with weld. Over that they put a patch made of 8th inch aluminum that was extended past the crack an inch on all sides. They welded that in place and grinded it down a tad to make it look okay. The most difficult part was getting the whole thing clean enough to take a decent weld, so put alot of emphasis of cleaning. I don't know amperages, etc. Good luck.

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Mims, FL

Thanks Maximus, I like the idea of the flat stock overlay after filling of the vee. That should hold in anything. Better than new, and a fun little project too.

[youtube]http:/www.youtube.com/watch?v=N-cv3R4fWZc[/youtube]

It's been about a year and a half since the repair, and it is holding up 100%. I've sailed it in all kinds of conditions repeatedly.

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Mims, FL

Good luck with the weld. I had the same problem with a 1979 H16. The weld lasted for about a year then recracked in the same place, but I think the weld was not of great quality. I eventually replaced the corner casting.