Join Date: Apr 2003
Location: MPLS, MN
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Re: SMOKE !!! I Hate SMOKE !!!
You know what the solutions are, you just don't want to hear it. Aluminum alloy welding rods typically melt at 700+° so your not getting a propane or MAP gas torch anywhere near that hot to melt the alloy to the head. The head needs to be heated beyond 700°, not the alloy rod. It also has to be perfectly clean since it doesn't use any sort of flux. At least not the rods I've seen. It also takes practice to solder with these rods.
What caused the stripped holes and broken off corners? Dried RTV in the bolt holes and when tightened they hydro-locked the blind holes. Either that or severe over tightening. You should always chase the threads of the valve cover bolts with a tap EVERY time when using this style of valve cover. After you fix the cylinder head, you might want to think about investing in a 1989 and up valve cover. Those are the ones that used the one piece gasket design. No RTV is required, and typically valve cover gasket can be re-used several times before replacement.
You could repair the one stripped thread with a heli-coil insert. That will fix that one but the others with broken off corners need to be repaired by welding. Yes they can be repaired, but it will require cylinder head removal, welding, drilling and re-tapping.
Last edited by 4 L-bodies; 06-01-2019 at 12:48 AM.
Reason: added info