Plasma welding aluminum to steel

[PlasmaPly]

Hi -
I'm pretty new to plasma welding (or any other kind for that matter) and have a project in mind that I'd like to try. I've welded both steel and aluminum but never to each other.

I have a steel oil pan on my 1991 Jeep Wrangler (4.0L engine) that I'd like to weld a thick aluminum rim to. I have a fellow who will machine the Aluminum plate (1/4" thickness... not cheap) to fit the bottom of the engine block (and match the holes, etc) and I want to weld this rim to the top of the steel oil pan. I have a small plasma welder (Mulitplaz) for the job.

Yes... this is all in an (expensive) attempt to stop the leaks (a Wrangler owners dream). It's also a learning experiment and I want to try it.
My other (very expensive) option is to knock up an all aluminum pan out of plate and weld the whole thing together.

Any advice on joining these disimilar metals (2011 aluminum to rolled steel)??

[jba]

Hi:

I vote for Fel-Pro.

Jeff

[ExpatWelder]

Originally Posted by PlasmaPly

Hi -
I'm pretty new to plasma welding (or any other kind for that matter) and have a project in mind that I'd like to try. I've welded both steel and aluminum but never to each other.

I have a steel oil pan on my 1991 Jeep Wrangler (4.0L engine) that I'd like to weld a thick aluminum rim to. I have a fellow who will machine the Aluminum plate (1/4" thickness... not cheap) to fit the bottom of the engine block (and match the holes, etc) and I want to weld this rim to the top of the steel oil pan. I have a small plasma welder (Mulitplaz) for the job.

Yes... this is all in an (expensive) attempt to stop the leaks (a Wrangler owners dream). It's also a learning experiment and I want to try it.
My other (very expensive) option is to knock up an all aluminum pan out of plate and weld the whole thing together.

Any advice on joining these disimilar metals (2011 aluminum to rolled steel)??

It's not gonna happen-------YOU cannot weld aluminum to steel.

[Tony D]

Get you some brake parts cleaner&blue silicone is that easy... scrape off the engine and pan, degrease it well and apply blue silicone on both sides of the rubbers at ends if it has em, and down the pan rails around bolt holes. carefully put it on there will be no leaks if you don't disturb the silicone and it will Have to be peeled off next time good luck...

[PlasmaPly]

Been there (felpro)... done that.

[blasphemy000]

I've had to deal with the leaky pan issue before. I got 2 words, "Clear Silicone." It comes in a pressurized can and when you press the nozzle it lays down a very consistent bead. Put that around the bottom of the block, let it set for about 15 minutes, then bolt the pan down and let it sit for 24 hours. You'll need a rubber mallet to get it back off, but it won't leak if done properly.

[KeithDas]

Ahh the glory of the almighty steeluminum its a shame that ferrus and non ferrus metals dont bond. Then agine i met a welder who tried her hardest to make it happen she spent approx 4 hours trying to make it work.