Intake Manifold Repair

This Ford Ranger 2.9 L intake manifold had a broken EGR valve mount.







As you can see, on the left hand side--bottom and top--it is broken through the threads on both sides.







We beveled the top to ensure good penetration into the crack.







Using Super Alloy 5 and an oxyacetylene torch, we made the repair in under 5 minutes.







After the part cooled, we sanded the welded area smooth and reinstalled in the car. Thick aluminum requires oxyacetylene, oxypropane, oxynatural gas, or oxyMapp gas to heat the base metal to the required 600 degrees. If your flux is not liquifying, it is because your base metal is not hot enough. To increase bonding strength, always add flux every time you add rod Always keep your flux bottle as close as possible to the repair area, because every time you move your torch away, the aluminum drops approximately 100 degrees per second.

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