welding ally sump

[cantfindausername]

Hi guys,

I've got an Aluminium sump on my car, and I've stripped out the threads on the sump plug.

Stripping threads on ally is a real annoyance for me... i hate it for stuff like this.

What I would like to know though, is will I be able to get a steel thread (bolt) welded into the sump rather than re-threading the aluminium?

I am kind of guessing the answer to be no because of the different temps needed for pooling both materials, but thought this would be the best place to ask.

Thanks in advance for any info.
Ant

 

[Justme]

What about brazing? Or use a helicoil kit.

Justme

 

[cantfindausername]

Yeah I guess they're both feasible options really. I want to get a oil temp sensor thread fitted too so maybe braizing would be the way to go.

 

[rtbcomp]

I'd use a helicoil with some sealant - don't glue the plug in though! AFAIK you can't braze to ally. You can get aluminium solder, but I don't know how strong it is.

 

[cantfindausername]

I've used some HTS2000 before and that stuff is awsome. Just a little concerned about heating the ally up really. Might get some more and practice a bit before dropping the sump. Or find someone to helicoil it. Still leaves the sensor fitting though. Mind you I could just get a lump and thread it myself and fit it the same way. hmm... got thoughts now.

 

[Justme]

Helicoil is a DIY (& possibly insitu) option.

Justme

 

[snowcat]

That sump would have to come off to do any kind of welding too it the TIG would need it spotless both inside and out, even when you have caseings removed and acid clean the buggers the oil still keeps seaping from someware..

 

[cantfindausername]

Yeah I'm thinking helicoil or insert of somekind might be a better option. I might see about giving the HTS2000 a go if I can get the heat into it.

The sump will be coming off regardless of what work I do to it because of the temp sensor install.

 

[bump]

For fitting a thread onto a sump, I've always brazed a nut on. Never had a problem this method.

 

[rtbcomp]

For fitting a thread onto a sump, I've always brazed a nut on. Never had a problem this method.

On aluminium

 

[cantfindausername]

That was going to be my question too.

 

[piman]

Hello all,

I had a cracked aluminium sump on one of my cars past and welded that with gas ( O|A). Not the prettiest of welds but did the trick.

That may be the way to fit the adaptor for the temperature sensor unless the sump has a suitably thick section that will drill and tap? (my sump was about 1\4" thick from memory so too thin to tap)

Alec

 

[Rusty]

Find yourself a second hand sump.

 

[piman]

Hello Rusty,

how does that help with fitting the temperature censor insert?
The stripped thread is a simple helicoil repair.

Alec

 

[Rusty]

Hello Rusty,

how does that help with fitting the temperature censor insert?
The stripped thread is a simple helicoil repair.

Alec

Hi piman, it might be worth looking elsewhere to fit the temperature sensor , maybe the oil filter housing or the engine block as there might be a blanking plug leading to an oil gallery,probably best to find out what kits are available,the sump kits sometimes reduce ground clearance depending on the position of the sump plug and you wouldn't want to knock one of them off on a speed ramp !

 

[lovelectricity]

someone stripped one in mine before i got it, they retapped it bsp put in a fitting and fitted a blank end to it. was gonna screw on a tap and refit blank end. oil change, no prob remove end, open tap.(my drain plug did stick out backwards though not str8 down). but helicoil is easy done it myself. all you need to know is what thread it was. as for the temp sens as was said look for a plugged hole after the filter.

 

[rtbcomp]

Be careful fitting a sender into a hole in an oil gallery - the bulb may restrict the oil flow.

 

[cantfindausername]

I've currently got the oil temp sensor fitted in a sandwich plate with the filter. However, this is withing 2" of the turbo downpipe, so it really acts more like a small oil heater.

I think I am going to look at an oil filter relocation kit to move the whole filter/temp sensor assembly away from the downpipe. This should remove the need for putting it in the sump.

I'm a little scepticle about drilling a clean start and tapping a new thread for the sump plug as I want to get rid of the ally threads, I would much rather have a steel thread insert.
Does anyone have a "how to" on helicoil use? Is it possible to just insert this on a drilled hole or does it need thread to bite onto? I've never used one before incase you couldn't tell.

Thanks,
Ant

 

[rtbcomp]

A helicoil is like a spring, the cross-section of the "wire" represents an internal and external thread. You drill and tap an outsize hole (using drill & tap supplied by Helicoil) and screw the insert in, using a special tool. You are then left with an internal thread the same size as the original.

 

[cantfindausername]

Right ok, think I get it. So by doing this it would give me the steel thread that I am after.

I guess it would be worth getting this done by someone with a kit, rather than buying seperate inserts and trying to match them up with an existing tap.