Repairing a broken aluminium casting

[jh2005]

I'm new to this and certainly won't make this repair my first project, but please could I have some advice on what might be the best technique to make this repair:
The casting is the body of a 12V wind generator from a boat and the mounting socket has fatigued and broken. An emergency repair has been made with epoxy but it didn't last.





To me it seems that I could either attempt to weld the pieces back together or grind it all down to fresh metal and build up beads to recreate the socket?
Any Suggestions please?

James

 

[the snooper]

will you need to strip it down so the heat doesn't destroy the electrical components ? if so its probably worth making the mounting socket a little more robust rather then simply repairing it

 

[wyn]

I'd also go with what the snooper says and get a new socket machined maybe with a thicker wall.
Cut the old socket out back to the strengthening ribs and weld the new one in

 

[AndyStobbs]

Arrghh cut a slot in each of those webs and slide two jubilee clips round the whole lot

 

[MattF]

What's the wall thickness of the housing? If it's thick enough to hold a short bolt, I'd be tempted to file/grind that housing smooth and bolt a shaped adaptor plate on there.

 

[the snooper]

Arrghh cut a slot in each of those webs and slide two jubilee clips round the whole lot

That would only weaken it further

 

[Pete.]

Looks like it's been mounted loose on that socket. Is the hole straight or tapered?

 

[jh2005]

Thanks for the replies. The diameter of the hole is 29 mm and straight, the wall thickness is 7-10 mm due to the octagonal shape of the exterior. It is possible to disassemble the innards of the generator to some extent so that the armature bearings can be changed.
I'm guessing the original failure was caused by a combination of stress and corrosion, not helped by the additional hole for the security bolt.
Fabricating an improved socket sounds like a good idea.

PS 27mm deep

 

[Pete.]

I'd go for what Matt says, a bracket shaped like a wingnut from 10mm steep plate with a plug for what's left of the hole. I'd make sure that hole is a snug fit so it can't wobble coz that's what's knackered it first time I reckon.

 

[gordon stephenson]

I have made excellent repairs to similar parts using the Techno-weld/durafix/HTS200 rods, check out youtube,it works far better than folks give it credit for.

 

[brightspark]

I have made excellent repairs to similar parts using the Techno-weld/durafix/HTS200 rods, check out youtube,it works far better than folks give it credit for.

il second that

 

[jh2005]

Thanks for all the advice and ideas!
James

 

[Rig Pig]

probably easiest to cut it off flat and make a twin U bolt clamp (or large s/steel worm drive clips)to go right round the body of the generator to a larger block of ally

 

[jh2005]

Reporting back: In the end I did the preparation myself to cut back to clean solid metal where the socket had been, and I removed the windings and electronics from the casing.

I then took it to a local specialist engineer was able to cast aluminium around a copper mandrel to give the basic shape of the socket and then run a few beads over the top to beef it up.

I tidied up the casting, refitted the windings and finished off with a fresh coat of paint.

James