Welding cast aluminum

[Nikolai]

I appreciate the feedback. I did die penetrant 2 times just to be sure and it is not cracked. Now whether it’s always been that way and I didn’t notice, or something put a crack in just the outside I’m not sure. If it was indeed cracked then it sounds like buying the case half would have been...

[Nikolai]

If it were to break open while riding and fill with water/mud then it destroys the internal parts at a replacement cost of about $1,000. Plus the hassle of removing it in the field and then trying to get back to the truck in 2WD.

The casting is not very thick in that area, feels like 1/8...

[Nikolai]

Almost positive it’s a crack. I’ve had it apart every year for the last 5 years and can’t believe I wouldn’t have noticed it before now, especially since I run the tap down the mounting holes each time. It also has a slight depression when you run your finger across it. That said, I am not 100%...

[Nikolai]

I found a crack on the front differential housing of my Polaris RZR. It’s slightly depressed like a rock got wedged between it and the frame and pressure cracked it. It is NOT cracked all the way thru, holds fluid just fine, no idea how long it’s been that way. I pull it apart every year for inspection....