- Location
- sunbury ,ohio
much better
Welders, waterbox....
- Thread starter Vumad
- Start date
Fro Diesel
creative control
- Location
- Kzoo
Geez vumad I thought you of all people would realize a true "bond" between materials is stronger than the individual materials alone. They must a used a gay marriage welder the first time! Glad they gave your box the rod this time!
Looks like a strong union has been achieved.
Looks like a strong union has been achieved.
Vumad
Super Hero, with a cape!
- Location
- St. Pete, FL
Boom. I expected the first box to fail, but I expected it to fail other places, not right down the center of the weld. This is the outlet side, opposite of the last picture.
BruceSki
Formerly Motoman25
- Location
- Long Island
That the new one? Time to fire their welder!
Vumad
Super Hero, with a cape!
- Location
- St. Pete, FL
Yes, rewelded the same box.
Again, I'm not a welder so I don't think it's fair for me to point fingers at an experienced welder. Why would the metal split down the weld? I expected it to split or burn through the edges of the weld. Not through it.
- Location
- St.Pete, Fl. - Daytona, Fl.
Might be using the wrong rod material
Did they re weld all the seams? If, not, they may keep breaking until all the previous stuff is ground out and rewelded because they were all done the same way as your first broken weld
Did they re weld all the seams? If, not, they may keep breaking until all the previous stuff is ground out and rewelded because they were all done the same way as your first broken weld
- Location
- Fort Worth
next time try JB weld.
you're welcome.
you're welcome.
Vumad
Super Hero, with a cape!
- Location
- St. Pete, FL
I have a new welder lined up and am changing the design to reduce the amount of weld. Expecting better results.
I'm curious how this goes. Hopefully you'll get it dialed in correctly and report back. 
Vumad
Super Hero, with a cape!
- Location
- St. Pete, FL
I'm curious how this goes. Hopefully you'll get it dialed in correctly and report back.
Still waiting on more metal. Have 2 of 3.
Ski actually ran real nice with this box and sounded great before it leaked, but I did have to turn the highs in half a turn so it was too restrictive.
- Location
- Vicksburg, MI
Th3g3rm4n4t0r
Brawlin' n Flippin'
- Location
- Ajax, Ontario, Canada
Find someone who can weld wood.
- Location
- Los Gatos, CA
That split down the middle of the weld... yikes. Wrong filler?
Vumad
Super Hero, with a cape!
- Location
- St. Pete, FL
I believe it failed the first time because they didn't use a rod. They just heated it up and used hopes and dreams to hold it together.
I believe it failed the second time because they tried to reweld a bad weld that had been soaked in oil without cleaning the oil or removing the botched weld.
The metal was also a bit too thin, so I believe it would have failed eventually anyway.
My new box is made from 0.080 tube instead of 0.60 plate and was done by a different welder.
I believe it failed the second time because they tried to reweld a bad weld that had been soaked in oil without cleaning the oil or removing the botched weld.
The metal was also a bit too thin, so I believe it would have failed eventually anyway.
My new box is made from 0.080 tube instead of 0.60 plate and was done by a different welder.
- Location
- Sacramento, ca
I am a welder for a living... like said the first box design was "fused" together. which is a HUGE NO NO for aluminum, and welding over a compromised weld is also a huge no no, but you also used .060'' material, way too thin for something that requires exhaust to flow out. Switch to 10ga or around 1/8'' thick and make sure the joints are "open" and just the tips of the sheets come together, it ensures 100% penetration. and you can also drill holes and use a small rod welded to each side to help it from expanding under pressure, but you shouldnt have it expanding just from a jet ski exhaust.
can you send you post a picture of the entire box though? maybe theres a design flaw that we could help with?
can you send you post a picture of the entire box though? maybe theres a design flaw that we could help with?
- Location
- central florida
We may even use thoriated electrodes here in Fl for less weld joint contamination. Anxious to see Vumad's new design.
2HIGH4U
Princess POWER
- Location
- BrisbaneAUS
This guys bang on-i also do this for a living
Vumad
Super Hero, with a cape!
- Location
- St. Pete, FL
You are correct on all of the above. The new box is made from a heavier gauge metal. It is also based on a 6" tube instead of a fabricated box, so it's easier to behold and fits in the hull better. Also, I got a different welder. The welds aren't super pretty but they are very strong.
The first welder which was a big shop didn't call me back when it was done, said they lost my number. I questioned the welds and they said it was fine. The job broke in about 10 minutes, they blamed the thickness of the metal, but then when they rewelded it, they used rod, and said in the future they will always use rod. I questions why they didn't use rod in the first place but they didn't have an answer. The box got some burn through of the material the second go so I knew the material was too thin, but I believe the weld breaking was due to rewelding over the first half as job.
I realized that the first of was going to fail. I had intentionally made it restrictive with access to the baffle to open it up for testing. I also recognized the first welds were bad but I was looking for a welder that would treat me right. The above was actually the 2nd welder, the 1st had kept it for 2 months making empty promises.
The new box has 2-3 hours on it with no problems at all. It would have more, but I haven't been out in a while.
Vumad
Super Hero, with a cape!
- Location
- St. Pete, FL
I appricate all of your help.