Cast Aluminum Repair

This is the repair of a Volvo Penta Helmut from a boat outdrive unit, this part covers the universals that drive the lower unit from the engine. It is made of cast aluminum and one of the ears was broken off, I cleaned it up and beveled both sides for a full penetration weld, found a section of ¼” x 2” flat stock (forged) which was also cleaned and beveled both sides. I clamped it to a piece of angle to keep all parts straight and square. I then welded the flat stock to the helmut one side at a time. I ground the welds smooth, mocked up a template from the unbroken side so I would get the threaded hole in the correct location. I cut the new ear to match the existing ear. I had to build up the thickness of the new ear close to 5/16” on the back side. With my template and using a centering punch I marked the hole, and used the proper size drill bit for the tap, and completed the piece.
Below are the addresses my YouTube channel which I no longer have access to, my Instagram page, HRI Services welding Facebook page, and my Outdoor Pursuits Facebook page.

https://store.evolutionpowertools.com/collections/evolution-chop-saws
https://www.millerwelds.com/
https://www.doorcounty.com/
https://www.usa.canon.com/
https://www.youtube.com/@HRIservicesllcSturgeonBay
https://www.instagram.com/hri_services/
https://www.facebook.com/HRIServicesllc/
https://www.facebook.com/groups/218766029078898