Repair And Fix it

Reference a tap chart to determine the drill bit size required for the threaded hole.

Secure the drill bit in a drill motor. Cover the end of the drill bit and the surface of the aluminum with cutting fluid.

Place the point of the coated drill bit on the aluminum. Pump the trigger of the drill motor to drill into the metal. Apply additional cutting fluid to the aluminum as you drill.

Secure a tap in the handle of a tee-handle tap wrench. Apply cutting fluid to the threads of the tap. Pour cutting fluid into the drilled hole.

Turn the tap handle clockwise to thread the tap into the hole. Reverse the direction of the tap when you have difficulty turning the tap into the aluminum.

Remove the tap from the threaded aluminum hole. Run a wire brush around the threads of the tap.

Thread the clean tap back through the threaded hole.

Spray penetrating oil where the bolt meets the thread. Let it sit for a few minutes so the oil can penetrate the thread.

Place the wrench around the bolt head. Slowly apply greater and greater pressure until it comes loose. Use an adjustable wrench or one that fits the head of the bolt perfectly. Do not round the head of the bolt. If the bolt head starts to become rounded by the wrench or requires greater pressure to loosen, use a pair of vice grip pliers instead.

Soak the area where the bolt is secured in penetrating oil overnight if you have not been able to loosen it. Slowly apply greater and greater pressure with vice grips until the bolt comes loose.

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.

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.

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.

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.

Level the engine block.

Clean the engine block with soap and water.

Heat the engine block until it reaches 1218 degrees F.

Apply aluminum repair material (braising rod) to the edges of the hole, heating it with an oxy-acetylene torch, then gradually build up enough material to cover the hole completely.