Charge Air Cooler Hole Repair

[oldnotslow]

Found a hole a little larger than 1/4", (.290) on the top tank of my CAC. Top mounting bracket broke allowing the CAC to slide forward just enough to rub on a bolt end in my grill, resulting in a hole in the aluminum tank. Wondering about the easiest way to repair this. Do you think J-B Weld would be satisfactory? Max boost pressure in the tank is about 30 psi. Now I know why my mileage has been so bad and it was smoking a little more! Would TIG welding the aluminum be the only way to go? Thanks for any help.

 

[JasonG]

A welded patch would be the best.
I personally would try the JB weld and see how long it held. Two part epoxy stick (water weld) might be better.

 

[Truck Shop]

Epoxy works best, we've sealed several CAC's with it. Even sealed fuel tanks using it. Sealed a pin hole in a radiator tube on a grain truck with it
four years ago. Still running that way and hasn't leaked yet.

Truck Shop

 

[Longhood]

I don't see why epoxy wouldn't work, but if you decide to get it welded get it done by someone who knows aluminum welding and does plenty, cast aluminum especially heat cycled can be tricky to weld, and easy to cause more trouble while attempting a repair, the repair could be done with MIG also, or even stick if the welder really knows his stuff, stick welding could be viable if the hole is somewhere that a back up strip could be inserted. Epoxy sounds like the best bet, even in the un likely event that the repair fails, you are only back to where you started, the other option would be to tap the whole for an aluminum pipe plug if the area is thick enough.

 

[oldnotslow]

Talked to two welding shops and both suggested two part epoxy, and welding as a last resort because of brittleness at the weld site. Used J-B weld slow/normal cure as it is substantially stronger than the 4 hour cure. Thanks for the input on this problem. I think this will be a permanent cure.

 

[Goodysnap]

I agree about the JB.The quick set is definately not as durable as the original.