64 Cuda Grill welding

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Garry

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Any real good welders out the care to chime in on some tips for this pot metal... Is it white, aluminum/zinc cast ? or other. will alum-a-loy rod work ? I have an extra real bad grill I intend to practice on. I suppose it will go to crap at about 800'... yes? any advise anyone ?
 
It's cast magnesium, so it isn't the kind of thing one can weld.
 
Whats wrong with it, I straightened one out with a small hammer and a block of wood...Looks like crap but Im going to paint it/chrome wrap it anyway. Careful, Magnesium can burn and you will not be able to put it out unless you cover it with sand or a PKP extinguisher. If you need to repair some lug mounts, there is a epoxy my machine supply shop sells that looks like its filled with aluminum oxide, sort of a black sand that dries as hard as steel. There are things out there to biuld up/repair almost anything.
 
Welding mag is possible, I've done it but it was only for practice. You need to find a very good welder who can weld anything i got a guy local in orange county called stanton welding. some of the Best work Ive seen. He has fixed a set of weber ida carburators for me when i accidently went too far opening up the float bowls.

Also you could find a early volkswagen machine shop who can weld. Vw engine cases are mag and they weld on them all the time.
 
Wikipedia says it better than I can.

Pot metal, also known as monkey metal, white metal or die-cast zinc, is a colloquial term that refers to alloys that consist of inexpensive, low-melting point metals used to make fast, inexpensive castings.

Although I've had decent results with several pot metal restorations, my technique has taken literally years to perfect and, to my knowledge, no other powder coater in the country really even messes with it. I do my repairs a lot differently than you're planning with high temp metal fillers and lots of body work ... but I'd never weld on it. I'm betting it will melt like a candle and if there's anything left of the original structure at all, it will be full of bubbles and pock marks.

I'm anxious to see what happens. Please get some pics along the way if you decide to go for it.
 
It's cast magnesium, so it isn't the kind of thing one can weld.

That's a red flag for me if true and I'm not sure it is. My '65 grill displayed a broken tab when I last removed. For years I have been thinking TIG weld on AC setting with no filler rod would fuse the break. I have not yet tried the repair though and should look at this topic more before trying.
 
If you cant access a tig welder they can be gas welded with aluminum rod. Probably a mig also. I have done the gas weld on them in the past.
 
When we tig welded mine, we both thought we were dealing with pot metal. If we knew it was magnesium, we probably would not have tried it. A magnesium fire can be pretty dangerous.
 
Hey spanky are you sure it is cast mag ? weldschoollincolnelectric.com according to his test on his video it is cast aluminum. White vinegar will not react to aluminum even if it has 6% mag. But you put it on mag and it will foam like hydrogen peroxide on an infection. I tried it and no reaction.....
 

Yes, I'm remembering now because it's been so long. When looking for a grill for my '65 Barracuda I ended up with a box full of broken grills, all of which just needed what looked like minor repair.

I brought them down to a great machine shop for repair, looking to fix the best one for myself and perhaps selling the others. We found that most of them were magnesium, but not all of them.

We guessed that perhaps the others were aluminum, or perhaps something mixed. We didn't proceed with anything because we didn't want to start a magnesium fire.

Next, I finally found a good grill at Wildcat Auto Wrecking. When I brought it to my local metal dipper they freaked out because the dip reacted like crazy with it. He handed it back and barked at me to tell him next time when I brought him magnesium.

What I don't have is great way of testing exactly what they're made of in terms of metallurgy. But it looks to be that some are magnesium and others are something else. If you look at them closely without paint you can see that they aren't the world's greatest casting. It could be that the metal they used changed by year or by batch. The ears break very easily and it's hard to bend the parallel lengths back into shape.

I do wish I could tell. But I though it was more important to dissuade anyone from trying to start a nasty fire.

Know what would be cool? Finding a near-perfect example of one and casting a new lot out of aluminum. I don't have access to casting anymore otherwise I wouldn't mind doing it myself.
 
A couple slats were cracked on my '64, had a bumper repair shop in Santa Clara repair them and straighten the ones that were wavy. Came out nice!
 
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