Cracked turbo brace - how would you repair or re-make?

[D60]

I think the angle is critical. Something like that I tack together in place, then remove and finish weld.

If I were trying to mash pipe as they did, I use my 50T press. It'll flatten 2-3/8" oilfield pipe

I don't usually care for the mashed pipe approach, it just feels ghetto (is often used to avoid coping on things like clothes line uprights and inexpensive furniture frames). But in this case you've already got the piece, so I'd probably repair vs fabricating from scratch.

Go buy a Hobart, Miller or Lincoln. It comes with a Man Card in the box <----this identifies as humor because inevitably someone will become defensive

 

[JHZR2]

At lunch today I took the brace to my local muffler shop that I’ve used a few times for stuff. They looked at it and were willing to repair. I told them no rush and they told me a few minutes.

The break was so obvious and clean that the fit and angle was easy to set up.

They welded it.

They did it for free, so I dropped a case of beer.

I have some Ace Rust Stop paint in high heat formulation, so I’ll sand/scuff the whole thing, then paint it, then in time dip it into woolwax.

 

[cptbarkey]

Good plan, Ace spray paint has worked for me in full texas sun with no fading and half the cost of Rustoleum.

 

[JHZR2]

Good plan, Ace spray paint has worked for me in full texas sun with no fading and half the cost of Rustoleum.

Yes I’ve used it on a range of stuff and have been happy with it.

 

[Dave Hess]

Yes, a stress fracture is weldable. I would weld it stronger than new. You can add material all the way up to even with the face of that hole.

Maybe he can ship it to you and you do the weld ?

Tig (BITOG member) has lots of experience welding.