Aluminum Cylinder Head Welding/Repair

Brodix BB-2 Chevy Alum. Cyl. Hd. valve train defect creating this damage.

This is a good example of our Alum. Cyl. Head Welding. First we T.I.G. Weld the damaged combustion chamber. We then digitize an adjacent combustion chamber.

Next we C.N.C. machining our welded combustion chamber. The repaired chamber is identical to the original chamber.

Then, we machine New Valve Seat Registers and Valve Guide Bores. We install new replacement valve seats and guides.

This Repaired Alum. Cyl. Head has over 200 ¼-mile passes with a 300hp N.O.S. System. Check out the BB-2 Saga on our “How We Do It” page.

T.I.G. welding repaired these damaged Dart Big Chief 707 c.i.d. Alum. Pro Stock Cyl. heads.

This I.H.R.A. 707 c. i. d. Pro stock car crashed at over 160 m.p.h. The front motor mount plate is bolted to the front of both Alum. Cyl. Heads. The crash impact tore the engine from the car.

The motor mount plate ripped off the front ends of both Dart Big Chief Alum. Cyl. Heads.

I.H.R.A. Dart Big Chief 707 c.i.d. Alum. Pro Stock Cyl. Heads T.I.G. weld repaired. (The pictures of the right hand Alum. Cyl. Head are lost.)

There is equal damage to both heads. This race car crashed in 1990.

Today in 2026, this engine with these 2 Dart Big Chief Pro Stock Alum. Cyl. Heads are in service.

Vtg. Maserati Comb. Chamber.
Leaky head gaskets can cause water corr. dmg.
Alum. T.I.G. Welding will repair this chamber dmg.

We have restored the chambers in this vintage Maserati cylinder head. The damaged chambers have been T.I.G. welded. We then digitized an adjacent chamber. Next we machine new valve seat registers. New valve guides and seat inserts will then be installed. All the Maserati chambers are machined to their original size

A brand new defective intake valve (the head fell off the stem) caused terrible damage to this aluminum cylinder head. Expert T.I.G. welding will repair all this damage.

These broken parts are fitted in place. We will preheat this aluminum cylinder head to 275°F.

We used our expert aluminum T.I.G. welding skills to repair this damaged Pontiac P6 cylinder head. Next we will pressure test the cylinder head and machine the deck. Then the valve job and combustion Chamber will be finished.

A great example of our expert T.I.G. welding aluminum cylinder Head welding skills. We repaired this aluminum cylinder in 1990. The deck surface cleaned with a .005″ cut. There were no Leaks.

This is a damaged I.H.R.A. Ford Pro Stock combustion chamber. We need to do some aluminum cylinder head welding to repair the chamber, and the valve set registers. We preheated this cylinder head to 275°F. Preheating the head reduces the current required to make proper welds.

Here we show the 800 cubic inch Ford Hemi Pro Stock aluminum head repaired. We digitized an adjacent chamber. Then we C.N.C. machine the damaged chamber to its original size. Last, we re-machined the valve seat registers. We then installed new bronze valve guides and seat inserts. (See “How We Do It” for details.)

There is a lot of aluminum cylinder head welding to be done on both these Dodge Viper heads. This photo shows all ten chambers damaged on these supercharged Dodge Vipers heads. The Programmer had too much timing or not enough fuel!

The deck surface cleaned with .003″ material removed. While welding near one of the intake seats I heard a cracking sound. I alerted the local engine builder to this damage. The engine builder blamed me for causing it. I suggested it was already cracked because there was no evidence of the seat being touched with the torch. What do you think?

I guess this Bad M.F. 385 took a hit and quit. A bad nitrous tune up gave this B.M.F. 385 new spark plug holes. We used a torque plate to seal the deck, so we could “back gas” the combustion chambers while welding.

Bad M.F. 385 Repaired. Deck required a .005″ pass to clean gasket surface. Notice we copied the tool marks from the digitized chamber into the repaired chamber. What can we weld for you?