Aluminium Engine Block Weld Repair – Custom Metal Fabrication, Warminster

This one looked like a simple weld at first glance, but aluminium doesn't forgive shortcuts. This customer had a cracked and holed engine block and was staring down a bill for thousands on a full replacement. Before we could even strike an arc, the whole block had to be pre-heated to around 200°C - aluminium expands and contracts fast, and skip that step and the repair cools too quickly, cracking straight back out. It's the reason a lot of places won't touch this kind of job. We ground back the damaged casting, cleaned it up properly, and got it heated evenly before welding the crack and hole closed with a full TIG repair. Every pass was built up carefully to keep the heat consistent across the block so the finished weld would hold under real running temperatures and pressure, not just look good on the bench. Once it cooled and was checked over, the customer was back on the road the same day for a fraction of the cost of a new block. If you've got a cracked or holed casting sitting in the corner of the garage before you go shopping for a replacement, give us a call in Warminster first - it might be a simple, affordable fix.