Zetec alloy sump

[Bonzo]

Thanks Mike

I removed the surplus flange earlier, with that gone it gave me a better idea of things.

Certainly looks like a nice straight forward job .... I think the bottom of the pan will have a coming off party in the morning & like you say, extend the rear of the pan

[Coozer]

The ali on the sump is a curious exotic mix (that means I don't know) that unless you are very good with the tig can become porous.

I would use the steel pinto one

Steve

[Bonzo]

Cheers for the heads up Steve

There were certainly a fair few tiny air pockets visible in the lump I cut off earlier !!

May drag the Tig out in the morning & try a few welds on the scrap piece

[onedayTM]

Hi ronnie, I've just finished my last job which was as a welder and have done some tig but not alot on ali but I'm willing to do it myself. What I want to know is how do you know what the ali make up of the sump is and then want type of ali rods do you use and want type of ali to use as the infill bit in the middle. Hope that is clear enough, hope you can help.
cheers
tony

[Bonzo]

I have almost completed the sump today

Taken a few mm from the alloy one .... Bolted it to the block to do the Tig welding .... Thanks for that tip mike, it soaked up the heat like a good un, would have had some distortion had I not.

Steve your dead right .... As far as cast alloy goes, I have never seen a casting with quite so many air pockets !!
Tig welds OK but trys the old patience a tad .... A tiny bit too much current & it's gone .... I guess about normal for this type of brittle casting

Tony

The standard BOC 5356 alloy tig filler rod seems to take just fine

I'll try to get some more photos posted tomorrow once I have it all done .

[Bonzo]

This morning I have managed to complete the sump alteration .... Assuming I don't change my mind & extend the rear end of it !!

Here's a few more pictures.

This was after the initial first cuts, I know it would of looked neater if I followed the shape of the sump plug but just decided to keep it simple !!



The next one shows the part saved for the sump base & the section of material that was removed.



This one is an example of the completed weld seam .... Was not aiming for pretty, just a functional leak free join.



All in all, not such a bad job to do .... No real dramatic moments .... Well besides blowing a massive hole in one side of it !!??
Got a bit excited with the heat, if you know what I mean

[Davey]

Nice job Ronnie, I might have to do something similar with the ally sump off the V6 but as I don't have TIG I'll have to learn to do it with oxy acetylene, should be fun . I could always take it to my mate to do but where's the challenge in that?

D.