I have some of those Harbor Freight Aluminum brazing rods around from a prior repair to a radiator on another car. I may try those.

I can see that stuff not sticking if the surface isn’t cleaned or if I don’t use enough heat. What worries me about it is using it on anything that takes some cyclic loading. When I put two things together it is quite strong but if I keep fatiguing on it like a window regulator it may not hold up.

Well, I may give it a try. I have a junk regulator on the shelf that not only has teeth worn to nubs. It has a cracked aluminum boss right next to the motor mount where it bends. I managed to straighten it out but the crack got even worse. I degreased it and drilled out the tips of the crack. It’s A good throw away piece to practice on.

I kind of hate that Harbor Freight Alumiweld rod because it puts out this irritating smoke. I was choking for an hour after fixing that radiator.

The regulator casting is made from a die cast aluminum. It is a pretty high quality casting. It may be unfair to call it “pot metal”. I’m tempted to see what my TIG torch will do to it. Well, that is today’s project. I’ll get back later.

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79 300TD “Old Smokey” AKA “The Mistake” (SOLD)
82 240D stick shift 335k miles (SOLD)
82 300SD 300k miles
85 300D Turbodiesel 170k miles
97 C280 147k miles