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Old 07-11-2014, 07:46 PM   #1
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Exhaust Repair?

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I have 2 OS 4-stroke engines that suffer from the same problem. These are a 70 and a 40 engine.

Due to crunches (neither being a result of my flying, incidentally ... honest!), the exhaust header pipe broke the threaded area out of the cylinder head. This is obviously a weak point, combined with the stainless steel header and muffler providing a major lever arm in the event of any hard contact.

No one around here thinks that it is possible to repair this area, and I tend to agree.

On the one engine, I have used a combination of 20 gauge wire and JB weld to construct a repair but I doubt that it will work. JB is basically an epoxy-based mixture and will soften at exhaust temperatures.

Has anyone else been able to get this area built up by welding and then threading?
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Old 07-11-2014, 08:21 PM   #2
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Re: Exhaust Repair?

With the price of glow engine now you would be better off picking up another engine or parts engine. Short of that just pick up a new cylinder.

Repairs can be done but always look like sh!t.

''engine hoarder''
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Old 07-11-2014, 09:01 PM   #3
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Re: Exhaust Repair?

The way the OP explained the situation you just know its gonna be asked, what happened?
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Old 07-12-2014, 12:08 AM   #4
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Re: Exhaust Repair?

you can repair it yourself if you care to spend the time, there are aluminum welding rods availiable, Canadian tire or Princess auto carry them. will melt with a propane torch. it does take alot of heat and it has to be super clean, a trick that seems to help as well is to give it a final scrub with a brass wire brush... anyways, I have repaired quite a few, even made pitts mufflers from aluminum. holds together very well. Just have to dissasemble the engine and make sure it is clean, then get it hot enough, the aluminum weld will flow like solder. I usually keep a flat screw driver handy to move the molten aluminum out of fins and up where I want it. you can leave the header in place and flow the aluminum around it but I prefer not to and bought a bunch of metric taps to retap it afterwards. of course there will be lots of naysayers out there, most will call anything down they haven't tried, this will be the same. Much cheaper then buying a new head. works fine. oh ya, last one I did was a OS 70. so don't tell me it can't be done.
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Old 07-12-2014, 06:44 AM   #5
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Re: Exhaust Repair?

Be careful Garry - I foresee a flood of broke heads in your mailbox! Good on you for trying and succeeding!
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Old 08-15-2014, 07:42 AM   #6
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Re: Exhaust Repair?

J.B. Weld disintegrates at 600 deg. F
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Old 08-15-2014, 09:49 AM   #7
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Re: Exhaust Repair?

Originally Posted by tommy View Post
J.B. Weld disintegrates at 600 deg. F
OK; and what is the temperature of an engine Exhaust?
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