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Old 03-15-2018, 10:55 AM   #1
TxCajun
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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.
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Old 03-15-2018, 05:13 PM   #2
B. W.
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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)
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Old 03-16-2018, 01:42 PM   #3
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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.
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Old 03-16-2018, 09:26 PM   #4
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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.
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Old 03-17-2018, 04:32 PM   #5
TxCajun
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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.
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Old 03-17-2018, 07:46 PM   #6
dennislbrooks
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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
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Old 03-17-2018, 08:04 PM   #7
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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
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Old 03-19-2018, 03:29 PM   #8
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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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