Chainsaw Repair

For once I got to save my own butt with the tig welder. I'm in process of rebuilding the turbo, trans and transfer case for my '02 Chevy 2500HD when I ran into a problem with the transfer case. The used car dealer said they put in a new transfer case when I bought it but it looks like they just epoxied the holes and slapped it back together.

All 4 bosses have deep gashes, 3 actually made it out of the case.

Finished and bead blasted again.

Slime balls!  Nice repair...

would be lying if i said i had never seen it done before. My cousin has a used car lot and that is minor compared to some of the things i have seen come through there. that seems to be a common problem on those chevy transfers. we have replaced 3 or 4 of them for  that problem in the last few months. never knew what caused it, we find the leak and tell him the transfer is junk. install a "new" junkyard transfer and move on. They are getting expensive though. Last one was around $600 IIRC. couple years ago we were buying them for $200-300. might have to look into fixing them for him

Nice job Shaun.   It just goes to show you cannot trust people to do things correctly.  What ever the reason.

Be glad you have the talent to do this type of work and save your self a ton of money.   I know over my 64 years I have saved a bunch of money by being able to do a lot of my own repairs.   

I was wondering did you do any preheating or just used the tig after bead blasting.   

No preheat, mag melts pretty easy so you can keep the heat in the whole part pretty low. The rest of the casting never got too hot to touch by hand.