I am (somewhat futile) attempting to fabricate a throttle cable braket and need to weld gussets on it. the material is a thin SS sheet. i get sugaring and cavitation on the OPPOSITE side of the weld, the bead itself seems to be ok, no burn throughs.
what do i do to alleviate the crap building up?

 

pretty sure you need to have it surrounded by an inert gas.

 

well yes, back purging is the way to prevent it, but how do you back purge a flat piece of metal?

 

I think it would be easier to get some angle metal stock or bend some 1/8" AL. But on with the backpurging. Make a jig using U channel metal with capped ends and place the over part getting welded. May I ask what engine this bracket is for?

 

thanks for the advice. i am fabricating a bracket for the CBR ITBs mated to a D16, using the stock CRX throttle cable. i do not think i can use a angle stock, as the shape of the bracket prevents it. i have also thought about using thicker aluminium stock, but the bracket at its flattest is around 4" long and i fear it will flex regardless.

 

No problem. If you post a picture of the itb's we might be able to give you some ideas.

 

i'll mock up the cable and the bodies tomorrow.
here are some photos of them without the cable



you can see the original bracket in the first photo, i am extending the length to accommodate the longer adjusting mechanism of the CRX cable.

 

Nice. Post a picture of where you are mounting the bracket if you can.

 

same location as the old one. i'll show some photos tomorrow.

 

what about getting some solar flux..... ive never used it but i would say this is the ideal case to use it based on what ive read about it here and there on the web.


mike

 

i'll look into it, thank you.

 

I have used a setup that looks like a sand blaster cabinet that you pumped argon into to flat odds and ends. It uses a ton of argon though so its really not cost effective if you're paying for it.

EDT.
Are you doing itb turbo?

 

yes, it is a CBR 929RR bodies mated to a custom manifold with a GT28RS turbo.

here is a photo of the discarded bracket with the burn through and the iteration of the bracket with today's final copy which is made out of thicker steel (i'll gusset it still, i think)

 

Solarflux will prevent the sugaring. But if this is just a throttle cable bracket, grind the sugaring off and call it done.

 

^^^^ I used solarflux in the past and works great.

Stefan

 

Back it up with a piece of copper.

 

you know, that is a good idea, it'll drain the heat off.

 

The copper will help, but I would put it in one of those argon tents..

 

It also traps argon on the backside. It's not as good as a full backpurge, but it gets pretty close with almost no effort.

 

the copper is a good trick for welding other materials where you want to prevent the weld from rolling over an edge on a thick block as well. why not just make the bracket in steel and paint it?

aaron

 

it is in steel, but it isn't thick enough to resist the flex. the direction has changed (again), with the charge plenum planned i think i'll incorporate the bracket into that instead.

 

purge block. **** a tent. really?

 

Honestly, control your current. You should be able to weld your material w/o melting the backside. If not use a purge block. done deal.

 

Use copper to bleed some heat off of the part or use an argon closet. If its just a throttle cable bracket grind off the sugaring, paint it, and call it a day.

 

use thicker material.

That throttle bracket is just going to bend with use.