Welding an Aluminum Cylinder Head

This is a 1997 Ford F150 aluminum cylinder head with corrosion eating right through the aluminum. The replacement cost for this part was $2200. Since there was nothing wrong with the workings of the cast aluminum head itself, Steve at Alternative Automotive wanted to save the aluminum head rather than replace it.





Note the hole is the size of a quarter. It's important to use oxyacetylene with cast aluminum parts due to the mass.





Heat the cast aluminum until the top layer starts to dimple. Then, fill the gap by building from the bottom with the Super Alloy 5.





After the welded cast aluminum head cooled, Steve finished the part with a disc sander





Here's a shot from above to see the down into the weld with no obstruction





This is why they are called Alternative Automotive, Steve welded the cast head in the truck and saved his customer a lot of money. The weld was made over a year ago and the truck is still running strong. Thanks Steve!

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