Repairing Cracks in an Aluminum Weld

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Welcome back to Lift Arc Studios! In today's video, Tay is tackling a common issue: repairing a crack in an aluminum weld on an intercooler for a truck. We'll walk you through the quick and straightforward steps to get an intercooler back in top shape, ensuring it performs efficiently and reliably.
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Produced & Hosted by: Tay Whiteside
Filmed by: Tay Whiteside and Walker Hooper
Featuring: Aaron Dykstra, Spike Geffert
Edited by: Walker Hooper
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Any technique or methodology shown in this video is purely for entertainment and informational purposes only. Lift Arc Studios and their associated craftsmen are not liable for any injury or damage to your shop or surrounding areas you man incur while trying to emulate these builds. Remember, be safe, have fun, work smart!

[@melgross]

I like to heat dirty aluminum to maybe 400 degrees for 20 minutes, or so. It helps getting some of the junk out.

[@brianmcmahon2216]

#5 cup might have helped direct your gas at the weld. Helps with dirty aluminum

[@larryreece1403]

I've welded a lot of intercoolers. Its amazing how much oil collects on the inside. I usually try to acetone the inside of the tank. (Expensive) but it usually helps with welding it up.

[@trnthpag]

Please please tell them you found it and to have a mechanic check it. The turbo passes a tiny amount of oil. But if its puddled up bad in the intercooler/charge air cooler there is a problem with the turbo or pressure in the engine. This is what causes an engine runaway on diesels. Ill send you my welding customers if you send me the ones full of oil 🤣🤣

[@ioanardelean1936]

Great explanation, great video,!! 😊

[@Funnyfabguys]

Iv done a few of these, #5 cup lots of cleaning and preheat helps a bunch.

[@jwm1222]

Spike must not of done his daily affirmation routine. 😂

[@Hu88le]

Great work as usual!

[@ahbushnell1]

Excellent video.

[@neilf.7222]

Oh the joys of repairing aluminum.

[@greekgods3399]

love it

[@ZILAwelds]

Nice job!

[@Metaz]

We like it! :D

[@wvrockcrusher]

Those are always very dirty to weld. I always try to clean the inside if possible and sometimes add a backpurge. Try a smaller cup on the torch next time and turn the gas up until you get some turbulence in the weld, then back off from there. It's always a trial and error to weld this stuff because you never know exactly what material you are dealing with.

[@stevemccauley5734]

Tay there’s a special episode on Steve Morris’s channel where he went to a famous welder’s shop. You should watch it.

[@johnpope4464]

You know what you are doing, I see other welders that don't drill holes

[@someyoungguy6990]

Ha that's funny you mentioned boost, I said the same thing. Could I also suggest plating the end cap joins as it may also be flexing the welds from the thousands of times it's hit boost.
Kind of the unholy trinity of fab work, undersized material + "Sema" welds + BIG boost = boost leaks for days.....!

[@TBJK07Jeep]

I’ll agree with with others, number 5 cup would probably help. I found with a number 8 on aluminum, the arc tends to wander a bit more with inconsistent cleaning.

[@jr3628]

could filling the cooler with argon (backpurge?) have helped?

[@MichaelAllanFrancisSheaver]

Random question to feed the YT algo for you: No soapy water pressure testing for QA? Jus' askin'!

[@907jl]

Wonder if the cracking was caused by the wrong filler rod being used on the original welds? If they used ER5356 filler, it is subject to cracking if the welds are exposed to sustained temps of over 150F. Not sure how hot this part gets, just thinking out loud.

[@trnthpag]

I see this alot on semi trucks as a mechanic. 9 times out of ten its usually the radiator gets replaced and the radiator intercooler/charge air cooler and condenser dont get mounted perfectly back together and then get torqued down. I seen all 3 crack from just mounting wrong. I think it torques the whole thing a little and it just cracks.

[@seanmoody3381]

How much boost was he running

[@smedleypdolittle]

Make them steam clean it inside, first, next time!

[@daveayerstdavies]

Back purge might have been helpful.