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How to Repair Cast Aluminum

A large variety of items are made out of cast aluminum, including cars, motorcycles, boats, porch furniture, pipes and gutters. The reason aluminum is so widely used is because it does not corrode easily and therefore is a choice metal for objects used outdoors. Unfortunately it is also a relatively soft metal so it is easily dented, cracked and broken. You can repair cast aluminum by melting an aluminum razing rod to patch any imperfections.

Instructions

1

Clean the area thoroughly. Use a wire scouring sponge and a heavy-duty metal cleaner to remove any dirt and grime from the aluminum you are patching. If you are reattaching two pieces of aluminum that have broken apart, such as a furniture leg, clean both pieces. Wash off the cleanser with water and dry the aluminum. Any foreign substance on your object will keep it from binding with the new aluminum.

2

Light your torch and hold it to the area that needs to be repaired. The area must reach 735 degrees Fahrenheit in order to melt the aluminum brazing rod. Do this outside or in a well ventilated area. Melting aluminum gives off a harmful fumes.

3

Hold the aluminum brazing rod in steel tongs to protect your hands from the heat. Rub the brazing rod on the heated part so it begins to melt. If you are filling in a dent or hole, allow enough aluminum to melt so it fills the area. If you are connecting two pieces of aluminum back together, melt enough of the brazing rod just to cover the area of one broken end. Stick the other broken end to it and clamp into place. Allow the aluminum to cool.

4

Smooth down the repaired area, starting with a coarse sandpaper and moving to finer sheets to polish. You can also use a metal buffing tool. Hide the repair with a coat of paint or polish.