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Old 02-04-2023, 10:00 PM
Bermuda Blue Bermuda Blue is offline
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Default Cracked air horn - repairable?

Picked up complete and unmolested tri-power recently. End carb air horn is cracked at the air filter stud retainer. See attached picture. Can this be welded? What is the material? Any tips on how to weld this. I assume TIG is the way to go. If so, what kind of gas, electrode and filler?

I have included 2 of the carb tags for those who may be interested. The third was damaged beyond recognition.
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  #2  
Old 02-04-2023, 11:08 PM
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Welded? No. Brazed or silver soldered perhaps.

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Old 02-04-2023, 11:52 PM
wbnapier wbnapier is offline
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Ask the pros: https://www.carhornrestoration.com/

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Old 02-05-2023, 02:09 AM
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Many of the end carbs I restore have the airhorn cracked similar to your picture. I apply JB Weld to the surface of the crack and squeeze the airhorn in a vise to force the crack to close. Wipe off the excess JB Weld and leave it in the vise for at least 12 hours.

Or, you can apply heat carefully to the left and right "beams" (since the zinc melts at a low temperature), while squeezing the top in a vise to force it into position. This closes the crack,. You can apply Super Glue when releasing the vise and squeeze the crack tightly shut, wiping off the excess Super Glue and leaving it in the vise for at least 12 hours.

Both these methods have worked for me.. You can buy steel replacements for the air cleaner web if you're not concerned about originality. With the air cleaner in place, the web is not visible.

I have not seen a successful solder or weld done to repair these cracks.

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Old 02-05-2023, 02:50 AM
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If you use super glue dust it w baking soda this make it MUCH stronger. In fact some airplane props are field repaired this way by the military it’s so strong.

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Old 02-05-2023, 12:57 PM
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Quote:
Originally Posted by turbo69bird View Post
If you use super glue dust it w baking soda this make it MUCH stronger. In fact some airplane props are field repaired this way by the military it’s so strong.
That’s interesting! Please elaborate on the process. Baking soda on part 1st, super glue 1st???

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Old 02-05-2023, 01:22 PM
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Quote:
Originally Posted by wbnapier View Post
Wrong kind of horn.

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Old 02-06-2023, 10:26 AM
chrisp chrisp is offline
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Leave it alone & just install a flat thin rubber washer under the wing nut to hold down & it will not loosen lid.

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Old 02-07-2023, 01:19 PM
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Quote:
Originally Posted by chrisp View Post
Leave it alone & just install a flat thin rubber washer under the wing nut to hold down & it will not loosen lid.
That's an OK fix, but I prefer to fix the crack for cosmetic reasons. As I suggested, another fix would be to cut out the cracked portion of the air cleaner web. Some racers do this for increased airflow. The remaining web is more than adequate to hold the air cleaner.

Many Tri-Power Rochester 2G & 2GC carbs have the air cleaner web distorted from heat and over-tightening of the wing nut. The cracks prevalent in the front portion of the web, I believe, are a result of overtightening.

I thought the comment by turbo69bird was sarcasm, but I did a little research and found that baking powder sprinkled on Super-Glued joints does, indeed increase the strength of the bond. Who knew?

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Old 02-07-2023, 01:42 PM
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I am totally in agreement with Dick on the no brazing, soldering, or silver soldering.

Have repaired quite a few by compressing out the crack, as Dick mentioned; then drilling and tapping for a 2x56 steel screw for support.

Of course, if the owner then uses an 8' cheater bar to tighten the wing nuts, it will break again!

Jon

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Old 02-07-2023, 04:51 PM
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Quote:
Originally Posted by GtoFM View Post
That’s interesting! Please elaborate on the process. Baking soda on part 1st, super glue 1st???
It can be done either way it’s just the chemical reaction between the two that makes it stronger.

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Old 02-08-2023, 02:11 PM
mgarblik mgarblik is offline
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Add me to the list who agree closing the crack and glue repair is more than adequate and looks good. I use a "super glue", with an activator and a fine filler powder in the kit. Extremely strong and durable. It really is amazing stuff. Have used it on all kinds of repairs. Works especially good on almost all plastics. Interior and exterior hard trim. Obviously, I have found it to work well to repair this common carb issue. www.max1.us

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Old 02-08-2023, 03:21 PM
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Quick question to the experts on this... Would you fix the crack prior to having the casting prepped and re-colored or after?
i.e. if the casting will be lightly glass beaded first.
Regards,
Joe

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Old 02-08-2023, 03:54 PM
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Prefer to do it after glass bead cleaning. You then, have a clean surface for better adhesion. Then, I have the dichromate done.

Seldom is the repair invisible. I smooth the repaired area with JB Weld, sand it, mask it, and paint the repaired web .

I had a local paint shop mix a can of iridescent satin spray that was color-matched to the dichromated carb body.

Here are two pictures of repaired end carb webs and two of a center carb before sanding & painting.
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