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Stick Welding Cast Iron Repair with Muggy Weld

9306 ratings | 1371370 views
Stick Welding Cast Iron Repair with Muggy Weld. Cast iron can be tricky to repair because it's prone to cracking. Follow along as I repair a broken cast iron exhaust manifold using Muggy Weld with no pre-heat. For this demonstration I used a 2 step process starting with an electrode that can withstand the dirtiest of cast irons followed by a cap that has excellent crack resistance properties. Although I believe a good pre-heat and a slow cool down will give you the best chance for success, i wanted to see how this rod would respond in a worst case scenario such as cold welding. It handled the thermal stresses excellent without any signs of cracking. This would be a huge bonus for parts too big to get a good pre-heat / cool down or for parts that are not cost effective to be removed. Hit the notifications! We are going to be doing some more experiments with these rods, including tig welding. More Cast Iron Welding Videos HERE https://www.youtube.com/watch?v=kzbcVb2UymA&list=PLfbf78fMz9VpweFv4IqUfrrNV6Vvro7Cd Link to Welder https://amzn.to/2MsrEWx Link to Welding Rod Information: https://www.muggyweld.com/ BUY Muggy Weld Rods HERE: 3/32 https://amzn.to/2SLmW6k 1/8 https://amzn.to/2M0z1ln MIG Welding Broken Cast Iron video: https://youtu.be/-8ct6Awo_2I ⇨ SUBSCRIBE to Brandon Lund DIY Builds: https://www.youtube.com/brandonlund THE TOOLS & GEAR I USE 🔴 https://www.amazon.com/shop/brandonlund Any commission earned from the above Amazon affiliate links all goes towards helping to support my channel. MUSIC By: Joakim Karud http://youtube.com/joakimkarud FOLLOW ME (for behind the scenes stuff)! ⇨ Instagram: https://www.instagram.com/lunddiybuilds ⇨ Facebook: https://www.facebook.com/LundDIYBuilds ⇨ Twitter: https://twitter.com/LundDIYBuilds For Business Inquiries: [email protected] Disclaimer: These videos are intended for entertainment purposes only and as such, you should not attempt to do any of the things you see me doing. Always read and follow the manufacturer’s safety guidelines before handling tools. Seek professional advice and training before using any welding equipment. Never operate any tool without wearing the proper personal protective equipment. Final warning, Do not attempt to do any of the things you see me doing!
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Text Comments (1348)
HiTechDiver (11 hours ago)
A little informative side step from the main topic: Many people know to drill a hole in material to prevent further cracking, but never thought about why this works. It has to do with Pressure = Force / Area (P=F/A). When you drill a hole, that force is applied over the circumference of the entire hole you drilled instead of the end of the crack. The pressure is diminished by spreading the force over a greater area. Obviously, if the force is too great, and the hole too small, it can crack beyond the drill hole. Been there.
LSX_ moe (4 days ago)
Nice job on the repair but that is a standard LS truck manifold and are readily available new for dirt cheap
Brandon Lund (1 day ago)
+LSX_ moe I completely agree. I think I paid less than 10 bucks for it. I picked it off the pile at the scrap metal yard.
LSX_ moe (1 day ago)
+Brandon Lund yea the process is solid for obsolete items and good for demonstration purposes but I'm saying that repairing a LS exhaust manifold is pointless
Brandon Lund (1 day ago)
I wonder if this process would work on an obsolete piece of cast iron?
LSX_ moe (1 day ago)
+109gnm cause I'm a mechanic and fabricator, and I guess his money is worth more than his time.
109gnm (1 day ago)
+LSX_ moe The new one will crack too. By the way, since you buy new stuff, why are you looking at this video. LOL
Howard Benoit (4 days ago)
awesome
Brandon Lund (2 days ago)
Thanks!
Allen Poe (5 days ago)
Dude, your eyes are SO TWISTED! Lmao I know you don't know what I mean but people from my generation do. Also, I thought that the reason cast metals are so brittle because the are "pre-stretched" . In other words all the ability for that metal to stretch was removed during the casting process. This is the reason you have to peen the weld, it shrinks and "tightens" the weld, at least that's how it was explained to me by a Navy boiler tech. lol I hope he taught me right!?
Brandon Lund (2 days ago)
3 eye surgeries later from metal objects in your eyes will do that to you. I have permanent scarring. I work night shift (12 hours shifts) so when I wake up, it always look like I smoked an ounce. I don't do drugs.
Tron80 (5 days ago)
I've a broken thick stove part to weld. Do you think I can weld after cleaning and with little steps like you? Was welded by a professional in pasts years but now is broken again in the same place Professionals tell me is hard to weld, it never return strong, I need preheat, is a complicate tecnique... What the drilled holes are made for?
Brandon Lund (2 days ago)
The drilled holes prevent the crack from propagating outwards. Cast iron that has been repaired will not be as strong as the original casting was before it broke. Typically repaired cast will break at the repaired area. Your best bet is to prep it well, use pre-heat, small beats with peining then controlled cool down in sand or an insulating fiberglass blanket.
Saadalah Thamri (9 days ago)
شكرا لك 👍👍👍👍👍
Brandon Lund (2 days ago)
Thanks Saadalah Thamri
outdoors Adventures (9 days ago)
remember, pre heat and post heat and you will be fine
outdoors Adventures (2 days ago)
+Brandon Lund I do a lot of welding with exotic metal for the nuclear and military industries, cast iron aint no big thing and neither should it be for anyone if you follow the right steps.
Brandon Lund (2 days ago)
Excellent advise!
Thomas Kallmyr (11 days ago)
Minns jag 1965-den 18 mai-på Tallvägen Uddevalla, Sweden-vägen mellan T.14 och T.8 -på Tallvägen,gick Walther Kegö som bodde i 14,och kom gående med sina "Freunds"-för att dricka "Schturmschnapps"-tror det vart vid 14-tiden,och han skrattade och gapade : "jag sköt ½-huvet av Kennedy-djäwelen..." och skrattade hjärtligt precis som om det vart något jättekul...sjuk och konstig....det vart han...den jäwelen-Kegö alltså.....klädd i mörkbrun manschesterkostym,med väst av manschester,byxor och röd slips med vit skjorta...han gillade Wernher von  Braun,och sade nån gång att hans brorson skulle bli Barn Läkare-nu vet vi ju att Lars Magnus von Braun,hade en son med Margareta Liechtenstein(Svensson)-som hon vart vår Fröken på Boxhultskolan-och han blev väl Barnläkare i slutet på 60-talet....hoppas hans bana slutar innan fler barn dör.....Barnsköterskan Anita Borlinger sade 1995...att : "Vi kallar ju inte honom för Liechtenstein,utan för "Greve Luxemburg"-men vi menar nåt mycket,mycket värre.....-menar Du Dracula,sade jag-hon tittade på mig,och jag förstod att många,många barn dött p.g.a. Draculas beslut om deras vård.....det hände vårt barn Daniel,att han höll på att råka ut sammma,om det inte vart för mig vore han död för 24 år sedan....men nu bor han i Hyssna,Bugared,Ansered,hos Annette Svensson(SverigeDemokrater).....ute i skogen...
Brandon Lund (2 days ago)
For those of you wondering what the translation is "Do I remember in 1965-May 18-on Tallvägen Uddevalla, the Sweden road between T.14 and T.8 -on Tallvägen, Walther Kegö who lived in 14, went with his "Freunds" to drink "Schturmschnapps" - believe it at 14 o'clock, and he laughed and yelled: "I shot the ½-hood of the Kennedy devil ..." and laughed heartily just as if it was something great fun ... sick and weird .... it where he ... the jäwelen-Kegö ..... so dressed in dark brown men's costume, with the vest of manschester, pants and red tie with white shirt ... he liked Wernher von Braun, and once said his nephew would be Children Doctor-now we know that Lars Magnus von Braun, had a son with Margareta Liechtenstein (Svensson) -which she was our Miss at Boxhultskolan-and he well became Pediatrician in the late 60's .... hope his path ends before more children die ..... Child nurse Anita Borlinger said in 1995 ... that: "We do not call him Liechtenstein, but for" Greve Luxembourg "but we mean a lot, much worse .....- do you mean Dracula, I said- she looked at me, and I realized that many, many children died due to Dracula's decision on their care ..... it happened to our child Daniel, that he was coming out of the same, if it were not for me he would be dead 24 years ago .... but now he lives in Hyssna, Bugared , Ansered, with Annette Svensson (Sweden Democrats) ..... out in the woods"
Brandon Lund (10 days ago)
Glad you enjoyed the video!
Erik Boink (12 days ago)
Heat red hot with torch set welder in dc reverse use a nickel rod have some fun
Brandon Lund (11 days ago)
Nice!
gallant19650 (16 days ago)
i'm a machiniste welder on the field,i like your way of doing this.....actually the trick is using your flux hammer all the time after you weld will actually help cause cast iron will retract fast as it cool so by doing this you are helping you cast to expend and as it cools ;)
Brandon Lund (11 days ago)
Thanks man!
mick hanks (18 days ago)
Just love watching a pro, thanks
Brandon Lund (11 days ago)
Thanks Mick!
James Fenton (18 days ago)
Brazing was always the best repair, all the old machinery I worked with was repaired in some way. Nothing like pre war iron to make someone thankful for electric starters. I had an old Hercules 4 cl hand crank start GE welder on a trailer, I was always wasted after starting that monster. GE welders were used building ships and I can't imagine using that stick welder to build a whole ship.
Brandon Lund (11 days ago)
I cant imagine a crank start welder. It can sometimes be enough of a chore just stretching the leads out for several floors in a building.
Volvo C303 Channel (22 days ago)
Thanks! I need to weld my manifold so this was great for me.
Volvo C303 Channel (21 days ago)
+Brandon Lund I saw the one with the MIG aswell. So i just need to get sand and something to heat it up with. Then its time to try. Thank you again.
Brandon Lund (21 days ago)
Glad I could help. Be sure to check out my other cast iron welding videos in the Cast Iron playlist and good luck with your repair!
ΟΞΥΓΟΝΟ ΚΑΙ ΜΠΡΟΥΤΖΟΚΟΛΗΣΗ
Craig Halvorson (24 days ago)
Can it be run on a AC machine thanks.
Craig Halvorson (24 days ago)
Thanks Brandon
Brandon Lund (24 days ago)
Steve, they can be run on AC or DC and Muggy Weld recommends welding electrode positive
Steve Armendariz sr (25 days ago)
Ok now you made a crack on the outer side of the exhaust manifold and then I noticed that the crack is now on the inner side of the manifold, so what happened to the first repair, I have repaired cast iron and its really not that easy to do.
Brandon Lund (25 days ago)
The manifold was prepped on both sides. One side was for the video you watched and the other side was for a future TIG welding video. Being the director, camera man, welder and producer, I never caught that I was welding on the side that you did not see me prep.
E Flanagan (28 days ago)
Thank you , but an actual cracked manifold will have fractured carbon and oil filled metal that has torsion pulling it apart at the crack , manifolds change dimensions with heat cycles , seen many gen 1 sbc manifolds not go back on an engine once removed .
Brandon Lund (27 days ago)
Thanks man! Burning it out would help if it was not welding good from being fouled. I built a spreader years ago using right and left hand threaded rod couplings for the reason you mentioned. It's been a while since I've replaced a manifold but without a spreader they can be a challenge to re-install.
Где техника безопастности ?!?!?!
Brandon Lund (1 month ago)
I don't know that technique
20Hertz (1 month ago)
Youtube, best teacher ever!
Brandon Lund (1 month ago)
Thanks!
Elias Vallecillo (1 month ago)
Beautiful job awesome video
Brandon Lund (1 month ago)
Thank you very much!
Bad Apple Garage (1 month ago)
Oxygen acetylene is the way to go on cast.
Brandon Lund (1 month ago)
I have had good luck using that process also.
whitey211 (1 month ago)
've been looking around my area for a shop that will fix some cracks in a cast iron piece I have and it's frustrating because no one works with cast iron. I'm not a welder but this doesn't look that much more difficult than the "normal" welding I've seen done. I'm kind of confused how this is like a lost art apparently.
Brandon Lund (1 month ago)
There is a lot of "you cant weld cast iron" mentality out there. I have had really good luck using varying processes. The truth is from my experience that you have better than a 50% chance that it can be welded. Most people don't want to bother because it's time consuming work and if it turns out that it cracks after it's welded than they will likely not get paid or even worse their name will be tarnished. Welding cast can be a crap shoot but as I said I've always had good luck with it.
TwoEdge Sword (1 month ago)
How to stick weld the aluminum?
Brandon Lund (1 month ago)
I don't have an AC machine currently which is needed to weld aluminum.
zach overby (1 month ago)
Do those lenox blades leave any residue other than the stock material behind? Thanks im learning allot
Brandon Lund (1 month ago)
No the blades don't leave anything behind and NO DUST in the workshop! I Love em!
Angela Prater (1 month ago)
Super nice
Brandon Lund (1 month ago)
Thanks Angela!
james worden (1 month ago)
clean up, preheat , an use ENI 99 rod , one pass , done.
Brandon Lund (27 days ago)
Thats also a great repair rod, however this was a viewer requested video and they were asking specifically about muggy weld products,.
Luc Gyre (1 month ago)
did this manifold had 2 cracks ? you welded on both side
Brandon Lund (1 month ago)
The manifold was prepped on both sides. One side was for the video you watched and the other side was for a future TIG welding video. Being the director, camera man, welder and producer, I never caught that I was welding on the side that you did not see me prep.
RuinedSpec (1 month ago)
This exhaust manifold is from a GM LS truck. It’s cast steel which is much more weldable. A lot of people have had success mig welding these manifolds.
Brandon Lund (1 month ago)
https://ls1tech.com/forums/forced-induction/1750208-what-truck-manifolds-really-made.html
David Billy (1 month ago)
Hahaha he said 3 1/2 inches of crack
Jager's 4xFORD (1 month ago)
would that rod work on a Turbo Charger housing?
Jager's 4xFORD (1 month ago)
+Brandon Lund I saw that video, thanks. Yes this turbo is cast, casting marks all over it. Cracks were a common problem with this vintage turbo.
Brandon Lund (1 month ago)
If its cast iron it will. I have some other videos on spark testing to help you determine what the metal is.
Jack Spratt (1 month ago)
great and very good vid. thanks.... my old welding buddy taught me most of what you showed but I heat the area but not very hot, I didn't have your weld rod but mine was made for cast iron use. I reversed polarity and burned for an inch then threw a welding blanket on the area and let it cool. once we brazed a cracked cylinder on the water side of a very old tractor and that was a tedious job but it worked for another 15 yrs. I ordered a diamond wheel today.
Brandon Lund (1 month ago)
Nice! Those old tractors are work horses! Your gonna love that diamond blade!
0-Zone (1 month ago)
11:35 Instead of burying in sand, could you wrap the cast iron in fiberglass insulation?
Brandon Lund (1 month ago)
Probably the best method actually! That way your not worrying about moisture in the sand
Wow that's so simple
Brandon Lund (1 month ago)
Thanks!
muhammad ilyas (1 month ago)
Amazing good job
Brandon Lund (1 month ago)
Thank you! :)
josue bendoy (1 month ago)
good job
Brandon Lund (1 month ago)
Thank you!
Lucifer & Sons Co. (1 month ago)
how do you prevent something from being welded if you are trying to repair a T slot for example any idea?
Brandon Lund (1 month ago)
Im not exactly sure but whenever I'm welding up to an area where I dont want the weld to flow, I have used copper to fill the void and I have also used fiberglass mat.
Kyle C (1 month ago)
damn that's alot of pecker marks from that chipping hammer
Brandon Lund (27 days ago)
maybe so but it's better than having the weld crack and the repair fail.
Steve Dunn (1 month ago)
thank you
Brandon Lund (1 month ago)
Your welcome! :)
DUB (1 month ago)
First time i know that cast iron can be weld §) No body told me this before!!! Well done mai
Brandon Lund (1 month ago)
Thank you very much!
MrPlaiedes (2 months ago)
I have NO IDEA about welding but you crushed that repair. Props.
Brandon Lund (1 month ago)
THANK YOU! I appreciate your support!
Dennis Monares (2 months ago)
Lol, I had a guy tell me that you can't weld cast metals. Very nicely done.
Brandon Lund (1 month ago)
Thanks Dennis! Show him this video LOL :)
Ash (2 months ago)
Thanks mate. That was very helpful
Brandon Lund (1 month ago)
Thanks Ash!
B Dogg (2 months ago)
I just weld that shit up with good ol flux core mig. Heat it up first, weld it and keep a little heat on it and let it cool slowly so it doesn't crack.
Nuffe (2 months ago)
its for b230 volvo 740
Nuffe (2 months ago)
the manifold! +Brandon Lund
Brandon Lund (2 months ago)
Huh?
george waite (2 months ago)
A good preheat and bury it in a sandpit when finish would help.
Coz McWillie (2 months ago)
Drilling a hole at either end of the crack to stop it spreading: who could've figured that one out?
Stevie Jeff (1 month ago)
You're father with your mother's assistance most likely. Ask him.
Coz McWillie (2 months ago)
I like people like this who can explain stuff clearly.
Brandon Lund (2 months ago)
Thanks brother!
Matthew Lewis (2 months ago)
Couldn't you leave the settings and just speed up a bit to avoid undercut?
Matthew Lewis (2 months ago)
+Brandon Lund thank you
Brandon Lund (2 months ago)
With undercut you would typically slow your travel speed so that more molten metal washes to the edges of the weld but that can result in blowing through so it's best to also lower the amperage also.
olegzakluchonii (2 months ago)
Wow could of fix my crackt boat block but I throw it away sux
Brandon Lund (2 months ago)
Sorry to hear that but now you know for future reference.
karim ezal (2 months ago)
اعجبني الفيديو
karim ezal (2 months ago)
واصل بالتوفيق
Brandon Lund (2 months ago)
Thank you very much!
karim ezal (2 months ago)
واص بدون توقف
Justin Bailey (2 months ago)
that looks like a ls manifold if so its cast steel not iron there a lot easier to weld
Sergio Specalsiki (2 months ago)
just a tip for you.... Do not have a closeup of your face
Brandon Lund (2 months ago)
Hey Sergio, thanks for the tip...i have one for you. Maybe if you werent such a rude, miserable a-hole people might actually like you and watch your YouTube channel. No wonder you only have 14 subs. BTW normally I block idiots like you but I'm making an exception today.
вернее было бы подогреть чугун градусов до 500, заварить и потом медлительно охлаждать, однако думаю в данном случае этого довольно
Brandon Lund (2 months ago)
I agree. I usually heat the part but I was testing to see how it worked cold. Cheers brother
claudio da silva rezende (2 months ago)
Brasil bolsonaro presidente 👍👍👍👍👍👍👍
Morgan Reyman (2 months ago)
I welded the old saab 900 turbo manifold with mig welding was better than the original shit , but they were red hot every driving, done a ton of japan cars to with mig , everybody has been satisfied , compared buyng new ones
Morgan Reyman (2 months ago)
maybe not in USA but in europa , nissan 4 cyl and other 4 cyl 1989 onwards europen builds, we in europa have many 4 cyl compared with usa ,im glad that these shitty cars has gone to scrapyards
blackdaan (2 months ago)
japan cars dont break down.. so you must be lieing xD
Fred Davis (2 months ago)
Your final shot where you try to tell everyone that you cant see the repair is not the same side of the manifold you welded on.
Brandon Lund (2 months ago)
Look again. Only one side was welded. The manifold was prepped on both sides. One side was for the video you watched and the other side was for a future TIG welding video. Being the director, camera man, welder and producer, I never caught that I was welding on the side that you did not see me prep.
my2centz (2 months ago)
I've tried heating cast iron and welding it and sometimes I have better luck then others but more failures then success that's for sure. Any help is definitely appreciated lol.
Brandon Lund (2 months ago)
Thats a tough question to answer because cast is fussy. The general rule is take your time, plan out your repair ahead of time, select a filler that you think will work best for your application and don't rush things. A preheat of 500 works good and try to keep the part at a constant even heat throughout your repair process. A grill or oven is great for this if you have access. Do very short weld beads then pein the weld. Put it back into the oven if things start to cool and keep repeating the process until its repaired. Once its repaired bury it in dry sand until it is completely cool to the touch (several hours). I have also heard wood ash works good to cool the part but I have not tried that method.
I've been welding LS manifolds with L56 mig for years with zero failures. A better test would be to try this on an OLD iron manifold.
+Brandon Lund Good idea. I'm not sure if those are considered "grey" iron, but the more brittle iron castings seem to require pre/post heat and exotic fillers AND they still crack like it's their job. I was just noting that for some reason, these newish gm manifolds act less like iron and more like steel (even if they don't throw sparks like steel when you grind on them.
Brandon Lund (2 months ago)
I've actually switched over to doing destructive testing on a cast iron pan. Cheers brother!
Rino Chaparro (2 months ago)
Porosity in the weld
Brandon Lund (2 months ago)
When you "wet" cast, thats what happens. Its virtually unavoidable with this process. If your concerned about pososity, I would choose brazing.
Damage, Inc. (2 months ago)
Will this weld my Mother In Laws mouth shut?
Flatus Antiquitous (2 months ago)
In my experience, not a chance.
Phillip Marquez (2 months ago)
Mmm I have never welded Iron but why not Tig for this? Also watching someone cut and grind without gloves makes me cringe lol.
Brandon Lund (2 months ago)
This is part of a cast iron welding series. I have tig welded cast and compared the results to all the other processes. It's in the playlist cheers!
Roger Hernandez Sr. (2 months ago)
Great Video 👍
Brandon Lund (2 months ago)
Thank you!
Bill Hanson (2 months ago)
My eyes r old.......repaired on one side. Finish shown on the other......
Brandon Lund (2 months ago)
The manifold was prepped on both sides. One side was for the video you watched and the other side was for a future TIG welding video. Being the director, camera man, welder and producer, I never caught that I was welding on the side that you did not see me prep.
Johnny Shackelford (2 months ago)
I noticed that too.....
Budget Project builds (3 months ago)
Great video 🤙🏼
Brandon Lund (3 months ago)
Thank you!
Bill Admond (3 months ago)
Thanks very much for sharing, I would pre-heat with a cheap gas torch and it doesn't cost much. And you guys kill me with these videos since I'm a retired multiskilled worker and need a garage to keep playing my hobbies!
Brandon Lund (3 months ago)
Thanks Bill! I recommend the preheat also and I can totally relate to needing a space to work. I watch a bunch of machining videos but I don't have the space to have any machines so for now I live vicariously through them Hahaha Cheers brother!
Kit Murphy (3 months ago)
What happened to your first weld starting out on the front? Why did you end up on the backside of it was there a problem or a crack?
Brandon Lund (3 months ago)
+Kit Murphy Thank you very much, but look closely. All the welding was done on the same side.
Kit Murphy (3 months ago)
But you started stick welding the front first. No? You did a wonderful job. I just wondered if there was a problem. I mig welded manifolds back in 80's and found that to be simple enough.
Brandon Lund (3 months ago)
The manifold was prepped on both sides. One side was for the video you watched and the other side was for a future TIG welding video. Being the director, camera man, welder and producer, I never caught that I was welding on the side that you did not see me prep.
Little Lilburn (3 months ago)
Good video, thanks!
Brandon Lund (3 months ago)
Thank you!
Gary Haynes (3 months ago)
Why is it that in the beginning of the video you are working on the outside (away from motor) of the manifold, then later you're showing us the inside (next to motor) ? Why ?
Brandon Lund (3 months ago)
The manifold was prepped on both sides. One side was for the video you watched and the other side was for a future TIG welding video. Being the director, camera man, welder and producer, I never caught that I was welding on the side that you did not see me prep.
Loosemouth Cowboy (3 months ago)
Let's pressure test that manifold with water
Brandon Lund (3 months ago)
She might be a leaker...Its got a huge gaping hole in the side from follow up testing:) lol
Robert Bock (3 months ago)
Great video. I now feel confident to do this job myself. Thanks
Brandon Lund (3 months ago)
Awesome Robert! I'm glad I was able to help!
Ralph Alvarez (3 months ago)
Think I just caught ARC EYE watching this lol
Brandon Lund (3 months ago)
Ralph Alvarez thanks brother!👍
Ralph Alvarez (3 months ago)
+Brandon Lund HAHAHAHA Good work though!
Brandon Lund (3 months ago)
You should have been wearing your safety squints lol :)
Logan Adams (3 months ago)
Buy a new manifold that one is junk
Brandon Lund (3 months ago)
It was just for demonstration purposes. I don't have a use for it.
Al Mor (3 months ago)
Is safe to weld a truck frame with a flux welder or had to be a stick welder can u help me with that question?
Harry New (3 months ago)
Great info but i would recommend thatyou drill half inch past the visible crack as that is wher the real end is
Brandon Lund (3 months ago)
Thank you! I appreciate your support!
Stephen Ostrander (3 months ago)
i would braze it
Brandon Lund (3 months ago)
Brazing is a great process, however, this was a viewer requested video.
Randy mack (3 months ago)
im maybe a bit too old school, but for that if I had to repair, I would first prepare a bed of sand, & a jumbo bag of charcoal burning, now drill as you said, then heat item up, with rosebud tip on torch, then get a friend to keep it hot while I use another torch & cast iron rod, & weld the crack, & yes I would ping it, but usually used a body hammer pick, I know not normal, but a go to hammer, then I would put layer of charcoal on sand & cover with couple inches of sand, & my helper still keeping part heated but slowly backing off on heat, for about 30 min of heated "cooling time" then lay item on the bed, then cover with couple inches of sand, then charcoal all around & over it, then more sand, allow to cool over night, & part should be ready. that looked too easy, in old days never had good luck with stick welding cast iron, even with preheat, but torch worked well, but very expensive, & all charcoal and a buddy to help heat, but I rarely do any, but not a "professional" but only a piece every 3-5 years.
Randy mack (3 months ago)
lol, gotcha, looks like something I would experiment if easy to replace, but if a pain to replace I will stick to old method,  I have seen older muggy weld for low temp aluminum repair, didn't know they made rods for sick welding.
Brandon Lund (3 months ago)
Randy, what you described is how I prefer to repair cast iron, however this was a viewer requested video and my first time using these particular welding rods. I wanted to see how they would respond to the cold welding method. In my experience if the part can be cold welded without cracking, the chances for success are huge when you start applying a preheat and controlling cool down. These rods claim to have excellent elongation characteristics. Based on this and other testing I've done with them, i have to agree.
Norfolkc (3 months ago)
This is nothing new did it years ago on exhaust manifolds you got to much power on, this type of rod has being around for years
Paul Burridge (1 month ago)
That's really helpful. Where is the link to your video please?
Brandon Lund (3 months ago)
Their website says they have been in business 30 years. This was my first time using their product. All i can say is it flows real nice and it was nothing like i have used in the past. I believe the composition is exclusive to them.
mobgma (3 months ago)
why didn't you bead blast it or vapor blast it?
Brandon Lund (3 months ago)
I could have but I feel like most viewers on this channel dont own one so I try to keep things in perspective.
DynamicOperations (3 months ago)
the undercut is because you are moving to quickly and not letting your puddle build up enough. you can tell because the shape of your bead is more pointed, and it should be nice even round curves.
DynamicOperations (3 months ago)
+Brandon Lund it works great either way but a preheat is always best
Brandon Lund (3 months ago)
+DynamicOperations interesting technique...I might have to give it a try. Are you doing this tecnique cold or with a preheat? I feel like this would be best suited with a preheat...
DynamicOperations (3 months ago)
+Brandon Lund i get what youre doing, i was just stating that was the true reason of the undercut not the machine settings. when im welding cast i tend to burn a little hotter and push my puddle back onto itself to help build it up and distribute the heat forward to simulate a preheat effect
Brandon Lund (3 months ago)
I tend to move fast with cast anyways because I'm concerned about heat imput. There is a fine line because you cant spend long in one place and you really dont want your base metal getting too molten. I'm trying to mostly wet the filler metal and not let much of the base metal get molten if that makes sense.
Ron Mcwhirter (3 months ago)
Need To heat the casting 500 degrees or so then weld with ni. rod
Brandon Lund (3 months ago)
Ron, as I mentioned in the video this was a viewer request for these specific rods. I wanted to see how they responded to cold welding, which in my experience welding cast cold has a higher chance for failure. The rods claim to have incredible elongation characteristics. Based on this and other testing I've done, I have to agree.
Angel Ramos (3 months ago)
Is your weld machine recommend to buy?
Brandon Lund (3 months ago)
+Angel Ramos FYI this is also my go to machine for stick welding and it's also a tig machine. It has a very nice crisp start and even runs 6010. I have a review on this welder if you search the channel. Cheers brother!
Angel Ramos (3 months ago)
Alright thanks boss
Brandon Lund (3 months ago)
It sure is Angel! It's a solid machine. If you want to know more about this welder I have links down in the video description.
Noah Mestas (3 months ago)
You bang on your piece way too much
Brandon Lund (2 months ago)
Not true. Compare blows per minute using a needle scaler vs doing it by hand. This has far less impact.
Tank Soldier (3 months ago)
Hey Brandon do you ever do brazing with a torch ? ,my uncle did everything that way and nothing ever had to be done over all ranch tested
Brandon Lund (3 months ago)
I sure do. I've done a lot of brazing actually. It's one of the first processes I learned on. Back in the day I was quite good at it. It's been a while so im rusty. It might be interesting to dig it out and practice a little. It's a very fun process and tried and true by old timers as you pointed out. Back in the day I could stack dimes. I doubt I could today without a bunch of practice.
Mike Baxter (3 months ago)
Everyone in comments WORRIED TO DEATH it might crack out again???? SO WHAT?? a brand new manifold might crack out again too! .. it's not her space shuttle .. cracked manifold won't even slow you down. The REAL trick is to weld it IN PLACE on the vehicle (if your going to remove it just put another one on) .. crap i've done it with regular 7018 ... run the car so it's hot ... hit the manifold with a torch for a while, weld it .. start the car again let it idle for a half hour. When it cracks out? weld it again ... by the third time the car is probability scrap anyway
Brandon Lund (3 months ago)
Right on Mike! I'm glad you understand what I was trying to show here. Cheers brother!
Robbie Holz (3 months ago)
Brilliant video
Brandon Lund (3 months ago)
Thanks Robbie! I appreciate your support!
Ashroyer86 (3 months ago)
Looked pretty good after the 1st pass. Looks like you may know how to weld.
Brandon Lund (3 months ago)
Thank you very much. I can’t take all the credit though, these rods flow pretty nice :)
98snakeeater (3 months ago)
nice I've cussed quite a bit trying to weld cast
Brandon Lund (3 months ago)
Thank you! It can be tricky welding cast iron but this rod makes it pretty easy though.
William (3 months ago)
Hi, nice job. I got a lot out of this video. Some items are hard to replace like vintage car engine blocks with cracked water jackets. So this will save a lot of engine lives I'm sure
Brandon Lund (3 months ago)
Thank you very much William! This was exactly the point of this video. Not everything can be replaced and this rod I feel gives the best chance of success for the user and the part being welded :)
Katelyn Tellez Vega (3 months ago)
Thanks, a like it .
Brandon Lund (3 months ago)
Thanks Katelyn!
MattBroncos 97 (3 months ago)
Where’s your gloves while grinding bro that’s a good way to lose a finger
Collin Zinn (3 months ago)
That is definitely not cast iron, that is cast steel. It is an exhaust manifold from a gm Ls series engine. Spark test are not always accurate. I’ve welded dozens of these with a mig/tig welded with no pre heat, with no failure rate at all! 0%
Brandon Lund (3 months ago)
It actually is cast iron. The manifold was independanly tested. There is also a link to the testing in the comments. You cant go by because it can be welded with non conventional techniques that it must not be cast iron. I've proven that numerous times in the cast iron welding series
Keegan Foster (3 months ago)
A beautiful weld!
Brandon Lund (3 months ago)
Thank you Keegan
Art Cobb (3 months ago)
The technique is right on. However with a real cracked manifold there is more issues to be concerned with. For one, the erosion/loss of original material along the crack on the inside and on the outside. Also it would have been better if your video had shown the same repair area from start to finish. The 72 was used on the part/ side normally facing out from the engine and the 77 repair showed the inside of the manifold which is next to the block when mounted. Obviously not the same repair area. I have welded for 50 years and have found out if there is a long crack along a manifold and it is repaired without being bolted down that it will sometimes warp the mounting surface and will have to be SHAVED/MACHINED FLAT along the mounting surface so that it will seal tightly along the engine surface. I have never used the Muggy Weld product but from what you said it sounds like it has the right composition and elongation features.
Brandon Lund (3 months ago)
Thanks Art. Unfortunately being the producer, cameraman and welder, things can get confusing. Only one side of this was welded. Both sides were prepped because one side was for this video and i intended the other side to be used in a future TIG welding video. The 72 and the 77 were both used on the same side. In other words, the side you saw me prep, was not the side I welded. Cheers.
rtm18990 (3 months ago)
you started on one side of the manifold and ended the video showing us the other side ground down.....why didnt you show the side you started on?
Brandon Lund (3 months ago)
The manifold was prepped on both sides. One side was for the video you watched and the other side was for a future TIG welding video. Being the director, camera man, welder and producer, I never caught that I was welding on the side that you did not see me prep
Mark Dietrich Cochran (3 months ago)
Hi Brandon, I love your videos especially since you don't judge us folks that have to work with what we have instead of what is ideal. I'd love to try some muggy weld. I'm a Monument Preservationist at Gettysburg National Military Park and we have tons of cast iron artillery carriages that we repair. Thanks for your ideas.
Prolific Invention (3 months ago)
"99" rod can work as well
Prolific Invention (3 months ago)
Stainless steel 309 stainless steel rods and these muggy welding rods work excellent for cast iron.
Brandon Lund (3 months ago)
Thank you very much! That's very interesting and impressive!
CRIPTOPOLICE Cx (3 months ago)
Nice
Brandon Lund (3 months ago)
Thank you!
Alessandro Novi Sad (3 months ago)
nice work.
Brandon Lund (3 months ago)
Thank you very much! I appreciate your support!
Scott Paulsen (3 months ago)
That root was far from perfect had slag pockets in it
Scott Paulsen (3 months ago)
That is well and good but where i grew up if there is a hole in something that's not to have a hole its not perfect and to weld over a slag pocket only esp in cast pulls the pocket into the next weld at best or adds to the existing one your end result was nice i was just pointing out the root was not perfect im a welder of 25 years ive done seen and heard alot all over this country but the root is the most important part of any weld no matter what the instructions may tell you always make it right cut off wheel end grinder get the slag out your welds will turn out better
Brandon Lund (3 months ago)
As you criticize my work I would tell you that cast iron is not pure. Rarely if ever can it be welded without inclusions. Typically you grind out the inclusion. With this rod the directions state grinding out the inclusion is not necessary and to weld directly over it.

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