Brazing aluminum zinc die casting ? - The 1947 - Present Chevrolet & GMC Truck Message Board Network

TxCajun · 03-15-2018, 10:55 AM

The shift lever holes on the "Shift Lever Housing" for my 1966 manual shift column are worn out oblong and cracked, so the shift lever roll pin which should be pressed in is just a wobbly fit.

Can these holes be repaired with aluminum brazing rod and then re-drilled? It appears that the commonly available rods have a melting point of about 720 to 750 degrees, but I have no idea at what temperature the die cast would melt or distort.

I also found ads for a brazing rod product called Muggyweld that has a melting point around 350 degrees, but the cheapest "kit" of rods and flux is around $50.

I was also considering a JB Weld repair of this area, but it seems that there would be a lot of stress at this pivot point. The JB Weld claims a strength of about 4,000 psi whereas the aluminum brazing rod is closer to 20,000 psi.

I haven't had any luck finding a replacement "Shift Lever Housing" locally or online.

B. W. · 03-15-2018, 05:13 PM

Post some pics if you can. Also, you might get more hits in the general message board (ask a moderator to move it)

tinydb84 · 03-16-2018, 01:42 PM

I just spent some time looking it up over on the welding web forum. Seems difficult at best.

Post a picture of what you are working on if you can. I am thinking that having bronze inserts machined and pressed in might be an option.

**PGSigns** · 03-16-2018, 09:26 PM

Have you been through the 60 to 66 parts section? They are out there. You could also become a supporting member and be able to post wanted ads in the parts section. There is not much the folks here don't have.
Jimmy

TxCajun · 03-17-2018, 04:32 PM

Attached are a couple pictures. The pivot holes should be about 7/32" (.218) diameter so that a 7/32" roll/spring pin would be a light press fit. However, the holes are worn in to an oblong about .241" x .281". There are also hairline cracks between the hole and the end of the casting boss so I don't think a bushing would work.

After cleaning up the casting, I found a part number cast on the inside: 3873134. In doing a web search, I found an NOS part for a reasonable price from AutoPartsObsolete, and ordered it so I have a solution.

When I have some time, I may use the old casting to practice aluminum brazing and see if that would actually work for future reference.

**dennislbrooks** · 03-17-2018, 07:46 PM

Maybe ------ brass/steel sleeve and locktite ----- reaming brass sleeve needs to be carfully done. Or a helicoil/locktite then drill out internal threads to 7/32

**mongocanfly** · 03-17-2018, 08:04 PM

i was thinking machine shop/bore/sleeve also.....but I went back and read where he said it was cracked around the hole and collar

sprint_9 · 03-19-2018, 03:29 PM

I JB welded an aluminum sleeve in mine. My holes were oblonged so I drilled them to the OD of the sleeve. Pounded the sleeve in, marked the cut marks, pounded it out and cut it apart and then JB welded the two halves in the collar.

It seemed to work ok but I haven't used it in the truck yet. There are pictures of it in my build thread about 4 or so posts down on the first page.

03-15-2018, 10:55 AM	#1
TxCajun Registered User Join Date: Sep 2017 Location: Cedar Park, Tx Posts: 209	Brazing aluminum zinc die casting ? The shift lever holes on the "Shift Lever Housing" for my 1966 manual shift column are worn out oblong and cracked, so the shift lever roll pin which should be pressed in is just a wobbly fit. Can these holes be repaired with aluminum brazing rod and then re-drilled? It appears that the commonly available rods have a melting point of about 720 to 750 degrees, but I have no idea at what temperature the die cast would melt or distort. I also found ads for a brazing rod product called Muggyweld that has a melting point around 350 degrees, but the cheapest "kit" of rods and flux is around $50. I was also considering a JB Weld repair of this area, but it seems that there would be a lot of stress at this pivot point. The JB Weld claims a strength of about 4,000 psi whereas the aluminum brazing rod is closer to 20,000 psi. I haven't had any luck finding a replacement "Shift Lever Housing" locally or online.

03-15-2018, 05:13 PM	#2
B. W. Registered User Join Date: Nov 2014 Location: Bigfork, Montana Posts: 1,137	Re: Brazing aluminum zinc die casting ? Post some pics if you can. Also, you might get more hits in the general message board (ask a moderator to move it)

03-16-2018, 01:42 PM	#3
tinydb84 Registered User Join Date: Jul 2009 Location: San Jose Ca Posts: 2,871	Re: Brazing aluminum zinc die casting ? I just spent some time looking it up over on the welding web forum. Seems difficult at best. Post a picture of what you are working on if you can. I am thinking that having bronze inserts machined and pressed in might be an option. __________________ David Used parts build: http://67-72chevytrucks.com/vboard/s...d.php?t=638991 My brother's Nova: http://www.67-72chevytrucks.com/vboa...d.php?t=727985 Rear suspension rework: http://www.67-72chevytrucks.com/vboa...d.php?t=750557 Instagram: myfabguy

03-16-2018, 09:26 PM	#4
PGSigns Senior Member Join Date: Jan 2011 Location: Hayes Va Posts: 4,569	Re: Brazing aluminum zinc die casting ? Have you been through the 60 to 66 parts section? They are out there. You could also become a supporting member and be able to post wanted ads in the parts section. There is not much the folks here don't have. Jimmy __________________ 60 to 66 Chevy and GMC window decals http://67-72chevytrucks.com/vboard/s...d.php?t=661131 Good friends, good food and a hotrod what else do you need? 1966 BBW long fleet Daily driver 1965 BBW short fleet Sold and going to a good home 1965 Suburban 2003 3500 Duramax 2005 Ultra Classic

03-17-2018, 04:32 PM	#5
TxCajun Registered User Join Date: Sep 2017 Location: Cedar Park, Tx Posts: 209	Re: Brazing aluminum zinc die casting ? Attached are a couple pictures. The pivot holes should be about 7/32" (.218) diameter so that a 7/32" roll/spring pin would be a light press fit. However, the holes are worn in to an oblong about .241" x .281". There are also hairline cracks between the hole and the end of the casting boss so I don't think a bushing would work. After cleaning up the casting, I found a part number cast on the inside: 3873134. In doing a web search, I found an NOS part for a reasonable price from AutoPartsObsolete, and ordered it so I have a solution. When I have some time, I may use the old casting to practice aluminum brazing and see if that would actually work for future reference. Attached Images

03-17-2018, 07:46 PM	#6
dennislbrooks Senior Member Join Date: Feb 2004 Location: Williamsburg, Ohio Posts: 1,764	Re: Brazing aluminum zinc die casting ? Maybe ------ brass/steel sleeve and locktite ----- reaming brass sleeve needs to be carfully done. Or a helicoil/locktite then drill out internal threads to 7/32 __________________ 1942 Chevy 1/2 ton Rod, 1959 GMC 1/2 ton Fleet Stepside, 1967 Chevy SWB K10, 1985 Corvette Coupe 4+3, 2015 Chevy Duramax reg cab 4WD W/T Last edited by dennislbrooks; 03-17-2018 at 07:52 PM.

03-17-2018, 08:04 PM	#7
mongocanfly Post Whore Join Date: May 2015 Location: Alabama Posts: 14,582	Re: Brazing aluminum zinc die casting ? i was thinking machine shop/bore/sleeve also.....but I went back and read where he said it was cracked around the hole and collar __________________ Mongo...aka Greg RIP Dad RIP Jesse 1981 C30 LQ9 NV4500..http://67-72chevytrucks.com/vboard/s...d.php?t=753598 Mongos AD- LS3 TR6060...http://67-72chevytrucks.com/vboard/s...34#post8522334 Columbus..the 1957 IH 4x4...http://67-72chevytrucks.com/vboard/s...63#post8082563 2023 Chevy Z71..daily driver

03-19-2018, 03:29 PM	#8
sprint_9 Registered User Join Date: Nov 2012 Location: 9 Posts: 862	Re: Brazing aluminum zinc die casting ? I JB welded an aluminum sleeve in mine. My holes were oblonged so I drilled them to the OD of the sleeve. Pounded the sleeve in, marked the cut marks, pounded it out and cut it apart and then JB welded the two halves in the collar. It seemed to work ok but I haven't used it in the truck yet. There are pictures of it in my build thread about 4 or so posts down on the first page.



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