I need to tig weld a crack in an old corvette pot metal head light bracket. What kind of filler should I be using. It has to be strong because the bracket is load bearing. Are there any tricks to this. I only have one chance and I can't screw it up. It was already sold to our customer $500 and it's the only one we have. Any help would be appreciated.

 

You should not attempt to weld pot metal, which has a high level of zinc in it. You have 2 choices: You can either epoxy it together, or braze it together using "alumiweld" or other eutectic hot brazing kits.

 

I don't think either of those are viable options. It has to be able to support the weight of the whole assembly. Why does zinc present a problem? This will probably sound stupid, but I had an idea of maybe getting a puddle going then trying to use another piece of scrap pot metal from a junk bracket that I have as filler.

 

Google pointed me in this direction. Hope it helps.

http://www.muggyweld.com/potmetal.html

 

Looks more like a braze. They say it's just as strong as the base metal, but I'm a little skeptical. Thanks for the lead though... Still up for suggestions.

 

Oxy-Acetelyn weld it with brass(brazing). Its strong and it will adapt to any type of metal. it will be in a different color however.

 

i hate that stuff - besides being toxic as hell, it like welding a sponge -

but, if you want to throw a couple bucks at it, i use a jeweler's torch. its just a tiny oxy - acet set up. i used some adaptors to step it down from the regulator on my regular torch and i use this cat wisker size rod for brazing and dip the flux because they dont make a pre coat that gage. you have a ton of control doing it this way, just bevel it in some from the back side and get it as clean as possible before hand.

good luck