TIG filler material for case repair - recommendations

[ballz338]

Do any of you guys have recommendations for what filler material to use on OEM 250R engine crankcase repair?  I am TIG welding up a crack around the shift shaft seal area.

So far i have experimented with 5356 filler rod on a junk case.  I didn't see any issues with this material but wanted to see if anyone here has experience with this.  I will also have to machine this after the welding is done.  If I remember correctly 5,000 series aluminum is not the best for machinability.

Any input is appreciated.

[Jerry Hall]

Do any of you guys have recommendations for what filler material to use on OEM 250R engine crankcase repair?  I am TIG welding up a crack around the shift shaft seal area.

So far i have experimented with 5356 filler rod on a junk case.  I didn't see any issues with this material but wanted to see if anyone here has experience with this.  I will also have to machine this after the welding is done.  If I remember correctly 5,000 series aluminum is not the best for machinability.

Any input is appreciated.

I would use 4043 on any area that requires strength on a die cast case.  The 4043 is a little more flexible and not as brittle.  4043 typically does not machine as well.

If I am welding up a gasket surface I will use 5356 because it is leaves a harder surface and better surface finish.  

Get all surfaces clean and a bright finish left by a carbide burr.  Do not try to weld an aluminum surface that has been cleaned by sand-blasting or sanding!!!

[sameltoe]

Seems like 4043 is just ol faithful in aluminum welding, it's pretty much all I've used, tig or mig.

[ballz338]

Thank you both!  

I am going to go with the 4043.