repairing cast iron handle

[SteveM]

I have this handle where the top broke off and got lost.

I was thinking of trying to make a new end and weld/braze it on.

You can see what it's supposed to look like here:


What are my options to repair this?

The missing part is pretty much an arm with a ball on the end.

I suppose casting an entire new handle would have to be considered an option. I do have another complete one to use for a pattern, and shrink probably won't amount to enough to worry.

Steve

[RMinMN]

Do you need pretty or authentic or just usable? If you need it to be similar to the original then casting is probably your best option if you have the ability to do so. If it just has to perform the function and odd looking doesn't bother you, steel is much more forgiving of being bumped without breaking but it will be harder to make it look authentic.

[SteveM]

Do you need pretty or authentic or just usable?

At some point, authentic might be nice, which is why I thought casting several might be a good idea.

For now, I'd like to get this handle working.

I just wish people would save the parts that break off - it would be SOOOOO much easier to fix.

I'm also thinking of casting the P&W plate behind it, which should be pretty simple as I don't need a two-sided mold.

Steve

[SteveHGraham]

I used stainless wire to MIG cast iron, and it held just fine.

[Glenn Brooks]

Steve, this is kind of an old thread but did you ever fix the part? if so I would be very interested to know what you did And how it came out.

The two primary methods for welding cast iron are to use cast-iron welding rod with a rigorous application of preheat and postheat, or use bronze brazing rod.

Glenn

[LIALLEGHENY]

Silicon Bronze TIG rod also works quite well if you have a TIG machine.

Nyle

[b4autodark]

Silicon bronze, TIG would be my choice also.

[shorttrackhack]

I repair castings often, and don't hesitate to make the replacement piece from steel. Silicon bronze works, but it is much like brazing. Nickelweld 59 and 99 both work well, but cost is considerable. TIG welding is the method I prefer, and my rod of choice in used piston rings. The rings contain enough iron to rust up like the casting, and when metal finished, the repair doesn't stand out like a sore thumb due to a bright sliver weld through the part.

[pigpen60]

Ive heard TIG with AL bronze works good. Ive done the mig and I have TIG'd with 309 both worked.