Cast Aluminum repair (mailbox post)

[Brian Hess]

Someone vandalized my cast aluminum mailbox post. How does one repair cast
aluminum? The post *fractured*. The broken piece was only a 1.5" stick,
which was cantilevered out, with the mailbox mounted on top.

Of course the stick is welded to a collar, and the collar is welded to the
post! I don't think I'm up to oxyacetylene welding; propane is as hot as I
go. Is it possible to drill a hole in the center and put some steel bar
(e.g. threaded lamp nipple) into it? Is there some structural adhesive that
can handle significant stresses so I could just glue it? (The surface area,
pi-R-squared seems awfully small to support a mailbox full of mail.)

Any assistance appreciated,
Brian

[Neil P. Fallon]

Why not bring it to a local technical school that teaches welding and have
them repair it?

Neil P. Fallon

Brian Hess <b...@active.com> wrote in message
news:HhoY3.273$O65.4133@client...

[Rock]

Here is a link to a site which has a very good product for "welding"
aluminum (cast or extruded) using an inexpensive propane torch. I was very
skeptical when I first used Alumaloy, but it is a quick, easy and durable
fix for aluminum repairs and connections.

http://www.alumaloy.net/

Rock

[Lberk]

I've used epoxy putty and it works pretty well. Why not for something like
this?

Larry Berk

[Jim's Repair]

In article <HhoY3.273$O65.4133@client>,

b...@active.com (Brian Hess) wrote:
> Someone vandalized my cast aluminum mailbox post. How does one repair cast
> aluminum? The post *fractured*. The broken piece was only a 1.5" stick,
> which was cantilevered out, with the mailbox mounted on top.
>
> Of course the stick is welded to a collar, and the collar is welded to the
> post! I don't think I'm up to oxyacetylene welding; propane is as hot as I
> go. Is it possible to drill a hole in the center and put some steel bar
> (e.g. threaded lamp nipple) into it? Is there some structural adhesive that
> can handle significant stresses so I could just glue it? (The surface area,
> pi-R-squared seems awfully small to support a mailbox full of mail.)
>
> Any assistance appreciated,
> Brian
>

There is a rod that you can weld or solder aluminum with using the heat from
a propane torch. It will be available at a welding supply or auto parts
house that has welding supplies. It works well for things like repairing an
Al boat, tanks, and filling gouges, but I don't know about the strength for
your mailbox post. You may have to dig it up and carry it to a welding shop.

Sent via Deja.com http://www.deja.com/
Before you buy.

[Brian Hess]

Thanks, everyone. I may try that Alumaloy, just to see how it does. But
ultimately it will be dug up and welded "for real" by someone else. The
stress caused by weight at the tip of the stick is just too high. In the
meantime, it's going to have a plumbing "pipe fix" bracket holding it
together... How's that for a kludge? Thanks again.

[Bob]

There are welders with trucks that can come to your site.

Bob

Brian Hess wrote in message <1hLY3.432$Zo5.3794@client>...