Ford 1210 put a hole in rear axle housing. Pics. Fix ideas?

[Citydude]

As far as getting the drum off, and your re-tapping for larger bolts, find a flat bar and drill holes in it that will match the distance between the holes on the drum. Longer bolts to reach the holes you tapped and put the flat bar across the shaft tightening the bolts as tight as they will go.

Apply heat to the drum where it's on the shaft, then apply spray lube. Hit the flat bar thats on the shaft with a sledgehammer. Hope this helps.

 

[5030]

Per chance, did you put a magnet on it to see if it was CI or aluminum as it sure looks like aluminum die cast to me. If it was mine and I had access to a replacement, I'd just replace it and chalk it up to experience. Die cast Aluminum is very difficult to weld, especially when it's been exposed to oil as the oil migrates into the metal pores and it's impossible to get out and the oil residue will vaporize and cause weld inclusions. You can try but I suspect it will be a failure.

 

[JC-jetro]

Welding is good choice but yet I will cover the hole like I said in the earlier post to seal the hole and then get a thick peice of rectangular ductile iron plate and cover the whole area and passed 1" in all directions and weld it up. My choice is MIG but might need to heat the area and clean it good .

 

[pclose]

Thanks all! I appreciate this site so much! I got the brake drum off with a combo of citydude's help and the slide hammer. (Getting loaner tools at the Advance Auto is great deal!) Here is another picture of the hole with a quarter stuck next to it for size reference. What looked like a crack in the 1st picture was just bad light. I found available used parts but they're understandably a little pricey. I will take it to a weld shop first to check cost and confident level for a cast aluminum repair like this. Thanks again!

 

[5030]

So it is cast aluminum not cast steel...lol If the shop is upfront, they will tell you the chances of a successful repair is slim. Better off just replacing the part and being done with it.

 

[Mat4644]

Lucky it's in a no support area. Yes cast aluminum can be welded by someone experienced in aluminum welding. I did say experienced and not a welder who seldom works with aluminum. This is non structural repair. Get it super clean and epoxy repair will be fine.

 

[JC-jetro]

Aha, I thought t was Cast Steel, did you do the magnet test? it does not appear to be structural which is good. Atleast you have plan B , but I think you will be fine with welding one plate or just externally patching the hole.

 

[5030]

The issue with welding ANY aluminum that has been in contact with ANY type of lubricant is, aluminum has a certain level of surface porosity in it so the lubricant migrates into the metal itself and no matter how well you try to clean it, when it's heated, the lubricant will vaporize out and cause weld inclusions. Consequently, the chance of failure will be very high. If he can replace the part, that is what I'd do. Any competent weld shop or welder will tell you that.

 

[ruffdog]

Most dirty aluminum has a good chance of being welded by a knowledgeable welder. It may take a bit of time to burn the oil out with the TIG arc and with brushing with a stainless brush. If the OP has located a used housing, why not have a welder try welding this one once it is off? If the OP wants to patch it, maybe form a patch out of 1/8" aluminum and epoxy it over it.

 

[JC-jetro]

well Gents, i was not sure about aluminum in the casting. Ya'll know that I have Ford1700 and always thought my rear housing is cast steel/Iron. I did walk to the barn and put a magnet to my rear axle. It sure sticks real good. Now, I wondered what should 1210 any different.