How would you fix this-aluminum

redtom · Sep 4, 2020

This picture is the exhaust port on a Kohler v twin engine on a mower at my job. The muffler brackets broke and the muffler hung down. Both exhaust ports are worn on an angle about 1/8 inch. I need to get a new muffler to seal to it. The tube sticking out can be removed. Some thoughts: remove the studs and freehand face the cylinders with a grinder? weld the bad side and freehand grind, weld the flanges on the new muffler so the faces are angled? If needed the engine could be set on a mill for facing off. Your thoughts?

Steve@Advance · Sep 4, 2020

Weld it up and mill it flat would be the right way to fix it.

If you have the means to do the welding and machining yourself, that would be practical. But hiring it done not so much.

Finding a good used head would be cheaper and easier.

Dennis Minn · Sep 4, 2020

redtom,

My first thought is a single new/used head. Them use the removed one and have at it.

The other (dumb) thought is longer studs and a bunch of gaskets.

D.

caterpillar guy · Sep 4, 2020

Those little gas engines are more work than they are worth. I don't bother to fix them. I'd junk it. I hate gas engines. But yes either replace the head or weld and mill it would be the best method.

jon f mn · Sep 4, 2020

There should be enough material to just mill it flat and use it. Or you can tig weld it up then mill it. If you can't do those thins yourself a good used head should be easy to find.

redtom · Sep 4, 2020

I should have added the cylinder/head does not come off-all one piece with the block

NC Wayne · Sep 4, 2020

There are epoxies out there that can be used to build up the area that can take the heat, and be machined to fix the damaged area.

DoubleO7 · Sep 4, 2020

Good grief! How long was muffler doing that to the engine?

A little attention to it long ago would have been a a bit easier to fix.

Janicholson · Sep 4, 2020

Mill it flat using the stud holes as a perpendicular reference, then make a spacer to replace the missing metal. 2 gaskets. In my experience there is no polymer based material that can handle 800 degrees for very long. Jim

John M · Sep 4, 2020

If it were mine, Id go through the trouble of milling it down, but for work, Id slap 2 gaskets on it and let it ride. You mess up with welder and grinder youll be paying for it one way or another.

Old560 · Sep 4, 2020

Interesting. what kind of an engine has a cylinder head machine to the block as one piece. Just wondering.

rustred · Sep 4, 2020

well if a machine shop is doing the work best to get another head as labour alone would be the killer.

Stephen Newell · Sep 4, 2020

Difficult to tell what it looked like when it was new. If it broke off chances are a repair would break off faster. I'm thinking you need to have a machinist make a repair part heavier than it was and then welded on.

fdt860 · Sep 4, 2020

Speaking about epoxies, there are some specamial exhaust sealant that are working great. I think that if you can engage the exhaust in the hole lived empty by the short piece of pipe and put a sealing ring like on 2 pieces turbo manifolds, you will be good to go.

redtom · Sep 4, 2020

Kohler 2 cylinder V on an exmark zero turn. New engine is $1500

How would you fix this-aluminum

redtom

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Steve@Advance

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Dennis Minn

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caterpillar guy

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jon f mn

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redtom

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NC Wayne

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DoubleO7

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Janicholson

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John M

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Old560

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rustred

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Stephen Newell

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fdt860

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redtom

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