Just wanted to update everyone. I ran my repaired pulley for about 6 hours now and so far so good. Planed several thousand bdft of lumber with it. Not gonna lie, I was pleasantly surprised it held together. Still plan to stay out of the plane of rotation as much as possible! Thanks to all who shared...

How much preheat would you suggest? It was at 400 as measured with my IR gun. Not melting the cast was the goal but as I added heat and played around trying to get the AlBr to wet in, some got melted. I definitely worked my way up in amperage from not enough to too much and nothing seemed to work. M...

Coldman wrote: ↑Sat Dec 04, 2021 5:11 pm The very first photos showed some of the run off balls. It would be interesting to break a couple of them off and see if they're magnetic. You might have some weird alloy going on than hinders the repair.

I was intrigued by this so I knocked off a couple BBs and they are quite magnetic.

Lots of pulleys are a cross between sintered and cast. Often very low grade with lots of impurities. That’s why there cheap to replace there designed to be a disposable wear part. If you know of a cheap source I'd love to hear it. I'm finding prices of around $800. Maybe I'm cheap! Been haunting eb...

Here are the pictures

Well today I finally got a chance to try the AlBr filler. Got to admit my tail is between my legs. After grinding it doesn't look quite so bad, but before grinding it was hideous. Couldn't get the filler to wet in. It wanted to bead up something fierce. I was on AC, advanced square wave, with 10% cl...

I poured over Harris' site and found lots of info but nothing on strength. Did find a couple other high silver products on the interwebs that claim 85-120 ksi, so that seems pretty comparable. Got some aluminum bronze headed my way; local shop didn't stock it. When that comes in I'll give it a go an...

Might have to bump up to high silver brazing. 45% or higher. How do think silver would compare to aluminum bronze for strength? This 20" wheel will turn at around 7000ft/min rim speed. You can bet I will be a good distance away and out of the plane of rotation when I spin it up the first time!

Yeah, brazing without melting the cast is the safe bet, that being said, I've welded a little bit of cast successfully myself, and my advice is to clean the HELL out of it, soak it in simple green overnight, then soak it in citric acid and scrub it down to bright shiny metal, then repeat both proce...

I guess that's where I'm going wrong is I shouldn't be melting the cast at all.

Cut a piece of plate in a triangle shape and make a web between the tubes?

Morning Folks I am trying to repair an old flat belt pulley but it's giving me fits. Had reasonable success repairing cast on several other occasions. I have tried TIG (DC and then AC) as well as oxy/acetylene to try to work this stuff but the cast just beads up and rolls off like water off a freshl...

Hi All, I've been welding since the mid 90's when my dad turned me loose with his MIG. He did some car restorations and we lived out in the sticks on an old farm so we fixed or built all sorts of stuff. I did a one semester welding class in tech college that focused mostly on gas welding and SMAW as...