Welding Headlight frame
The ORIGINAL and bestest
Joined: Oct 2000
Posts: 10,009
Likes: 240
From: Toronto Ontario
Toronto Events Coordinator
Originally Posted by Twin_Turbo
it's aluminium, dirty aluminium but it can be welded
Race Director
Joined: Mar 2006
Posts: 14,112
Likes: 28
From: Florida
Pot metal used in cars has a lot of zinc in it and any number/combinations of other metals, whatever was cheap and handy at the time. There are no standards like other metals and alloys.
The difficulty arises in the very low melting point of the potmetal around 700°F
There is a special alloy rod with a melting point below 400°F that makes it fairly easy to repair.
Will post when I find the file.
The difficulty arises in the very low melting point of the potmetal around 700°F
There is a special alloy rod with a melting point below 400°F that makes it fairly easy to repair.
Will post when I find the file.
Le Mans Master
Joined: Jun 2005
Posts: 5,447
Likes: 3
From: Syracuse NY
http://www.muggyweld.com/potmetal.html for pot metal
If it is in fact dirty aluminum maybe JBWeld would work?
If it is in fact dirty aluminum maybe JBWeld would work?
Tech Contributor
Joined: Aug 1999
Posts: 15,173
Likes: 3,982
From: Connecticut, USA
I tried the Muggy weld for this very job and it was not anything like advertised. I had to play with it a while to get it to bite in. I was repairing the tapped bosses the cover screws to and really had to build it up and then use a helicoil to fix. The repair appears good but the units have been rebuild and are sitting in storage so who knows if they'll hold up when back in the car?
I wasn't too impressed with the product but the web site demos look pretty easy.
I wasn't too impressed with the product but the web site demos look pretty easy.
Drifting
Joined: Oct 2003
Posts: 1,426
Likes: 1
From: VetteMOD
St. Jude Donor '05-'07
It is aluminum. Pot metal is mostly zinc. I have seen the headlight frames repaired by attaching a plate and glassing over the repair. If done correctly, it is a very strong joint.
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
Top 10 Most Expensive Corvettes Ever Sold on Bring A Trailer
Brett Foote
10 Things Every Corvette Owner Needs (2026 Edition)
Michael S. Palmer
8 Most "Only Corvette Owners Understand" Quirks and Problems
Pouria Savadkouei
10 Reasons the C6 Z06 is Still A Performance Benchmark After 20 Years
Joe Kucinski
How Much Horsepower Every Corvette Engine "LOST" in 1972
Joe Kucinski
Top 10 DOs and DON'Ts for Protecting Your Convertible Top!
Michael S. Palmer
Top 10 Most Explosive Corvettes Ever Made: Power-to-Weight Ratio Ranked!
Joe Kucinski
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Team Owner
Joined: Jun 2000
Posts: 38,923
Likes: 1,481
From: Southbound
Cruise-In II Veteran
Originally Posted by BBShark
It is aluminum....
My advice would be to take the assembly to a competent welding shop and let them have a look at it. They'll be able to tell you whether they can, or cannot, make your repairs.
Melting Slicks
Joined: Feb 2003
Posts: 3,053
Likes: 4
St. Jude Donor '03,'11
Originally Posted by Easy Mike
I've always heard these are pot metal. Years ago they could not be welded.
Mine were heli-arc (i think) welded back in 1981. They lasted until i replaced them about 2 years ago.
Welds were still strong. The mounting tabs where it connects to the metal V bar between the lights and engine had corroded.
Le Mans Master
Joined: Jun 2002
Posts: 8,339
Likes: 24
From: I can walk to MA
Fixed my front tab with a couple pieces of 1/4" aluminum ...
all tapped and screwed.
My rear slots were elongated, too .... just used large washers for this.
Looking from underneath at front tab:
all tapped and screwed.
My rear slots were elongated, too .... just used large washers for this.
Looking from underneath at front tab:
Melting Slicks
Joined: Dec 2005
Posts: 2,441
Likes: 0
Originally Posted by gtr1999
I tried the Muggy weld for this very job and it was not anything like advertised. I had to play with it a while to get it to bite in. I was repairing the tapped bosses the cover screws to and really had to build it up and then use a helicoil to fix. The repair appears good but the units have been rebuild and are sitting in storage so who knows if they'll hold up when back in the car?
I wasn't too impressed with the product but the web site demos look pretty easy.
I wasn't too impressed with the product but the web site demos look pretty easy.
Last edited by shafrs3; Nov 14, 2006 at 09:16 AM.
