broken turbo housing

[redrovertdi]

Any body have any ideas if/how this could be repaired, thought i would ask befor taking to it with the mig and possibly making it worse, its been a long week of every thing i touch turning to crap

[isuzurover]

TBH I think you would be better off buying or fabricating a new one...

However, you can weld it either using cast iron (or weldall) rods (both $$$) or a MIG. In both cases you need to heat it up with an oxy before welding, let it cool slowly, and stress relieve the weld afterwards (e.g. peen using a slag hammer or similar).

[disco_ute]

Are the turbos different between the 200tdi and 300tdi?
I have a 300tdi turbo and housing you can take off my hands at a bargain if you are interested.
Mick

[redrovertdi]

Are the turbos different between the 200tdi and 300tdi?
I have a 300tdi turbo and housing you can take off my hands at a bargain if you are interested.
Mick

The broken housing is a MTQ watercooled mitsubishi turbo made aftermarket for 300tdi s, i just fitted an original turbo back on[straight swap other than water hoses], but thanks for the offer

[roverrescue]

I have become a fan of SiliconBronze MIG for these sort of repairs.
I know, I know it was developed for welding body panels and other skin work.
And yes I know it wont be a structural weld.

But for cast housings of unknown temperament especially those cast 'whoflungdung' parts with made in China stamped on them. I have had much better success using the GMAW (MIG) process
- straight Argon and 0.9mm SIBronze wire as opposed to other techiniques.
The other benefit is that it is easily machinable after welding.

I have found if welding up cast using ER70S wire (standard hard wire) the finished weld becomes incredibly hard (martenisite perhaps - or just carbon pulled from the cast into the weld pool) to the point that even carbide tooling bounces. You can limit this a little with pre-post heat and peening or just use SiBronze

Assuming that is a standard 300-esque housing that has bolts supporting the central section and then the slip in horns, there would be very little load (other than gas sealing and heat cycling) on the broken portion. Clean up on the linisher, tidy up a weld groove and glue it back with the SIBronze would be my attack.

Something to consider if you have MIG and get to play with cast whatevers...

Obviously SiBronze is not a good option if the casting has significantly high structural loads applied to it... but in my experience cast iron/ cast steel is of such low quality these days the above is rarely a problem.

My most recent success with SiBronze was a flogged out hub. The hub nut had been run too loose, and the bearing cup had spun and worn out the hub surface. Luckily the land was still intact so I had a good depth reference. Chucked up the hub in the four jaw and dialed it in as best as possible off the good bearing surface. Cleaned up the worn bearing surface to about 1mm above diameter. Then slowly turned lathe while laying beads of SiBronze. Very easy to then machine it back to press fit tolerance. Effectively line bored the hub with SiBronze.
Worked well and hub now fits up beautifully and spins concentrically on axle.

This saved a hard to replace hub with only a few hours work. Obviously the SiBronze will be marginally softer than the original casting but I can cope with that risk.

Steve

[flagg]

Problem is that by the time you have the right wire etc you are laying out about the same as a 2 nd hand housing.. And there is a lot of room for error..

[redrovertdi]

Problem is that by the time you have the right wire etc you are laying out about the same as a 2 nd hand housing.. And there is a lot of room for error..

But its not a standard housing that is readily available

[roverrescue]

by the time you have the right wire
Hmm, after watching Keith Fenner use SiBronze to build up cast housing (he was using GTAW)
I just ordered this:
Silicon Bronze MIG Wire 0 9mm X 1kg Ercusi A Welding Wire Welder MAG Silicone | eBay

Even up here in Timbuktoo it arrived just a few days after ordering.

$60 is cheap as far as I am concerned. Already it has been used to save a hub ($100 ish) a 4WDCanter Brake drum ($250) and I used it to modify a brass fire extinguisher fitting so I could use the bottle as an air tank (un-obtainable)... I have maybe used 1/4 of a 1kg spool at $60...

Its not like you are going to lay down a 15kg spool of the stuff in a weekend!

S

[redrovertdi]

by the time you have the right wire
Hmm, after watching Keith Fenner use SiBronze to build up cast housing (he was using GTAW)
I just ordered this:
Silicon Bronze MIG Wire 0 9mm X 1kg Ercusi A Welding Wire Welder MAG Silicone | eBay

Even up here in Timbuktoo it arrived just a few days after ordering.

$60 is cheap as far as I am concerned. Already it has been used to save a hub ($100 ish) a 4WDCanter Brake drum ($250) and I used it to modify a brass fire extinguisher fitting so I could use the bottle as an air tank (un-obtainable)... I have maybe used 1/4 of a 1kg spool at $60...

Its not like you are going to lay down a 15kg spool of the stuff in a weekend!

S

Ordered that earlier today

[roverrescue]

Not sure what gas supplies you have - I have only run it with straight Argon which is the recommendation for panel work et al.

It is a little splattery and smokes like a hippy but the final bead lays down beautifully and will machine as smoothly as the surrounding cast material.

I had to spin the poxy little 1kg spool onto an old empty 15kg spool so it would fit in my feeder but that was no real drama.

Have fun

S