That’s a good idea using judicious heat from a torch to soften the aluminum a tiny bit. I cracked up my rear regulator trying to bend it back cold.

It turns out they are a high quality aluminum casting and they TIG weld easily. Also I was able to TIG braze new teeth on with silicon bronze filler rod. This stuff is slightly softer than steel so it is easy to shape using a dremel tool with a cutoff wheel. I flattened the faces of the gear with a disk sander.

From my old thread somewhere on this forum.

I just blobbed on some SiBronze like this.



Then I grind like this. The regulators have a slight whine to them because I didn’t perfectly match the tooth profile but they work well.



As mentioned the aluminum is weldable. I just used junk aluminum picture hanging wire to do this. It’s not pretty but it filled in all the cracks I made bending it out.

__________________
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

THANK YOU ! .

You skill set exceeds mine but that's a nice job .

__________________
-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

Wow. Unbelievable.