This cast aluminum oil pan from a Harley Dyna came in with a large tear in one corner. The ribbed wall was split open and the metal was peeled back, so the pan could no longer hold oil. It was a time-sensitive repair: the bike was down until the pan was fixed, and replacement pans for older bikes are not always easy to find quickly. We repaired it with TIG welding and refinished it so it looks like a factory pan, with no visible sign it was ever damaged.
The damage
The tear ran across the corner of the pan and up through the cooling ribs. Cast aluminum that has been soaked in oil is hard to weld, so the first job was getting the area clean and the edges ready before any heat went in.
TIG welding the repair
The corner was closed up with TIG welding, working in small sections to keep the heat under control on the thin cast wall. TIG gives precise control over heat and filler, which matters on cast aluminum where too much heat can cause new cracks or warping.
Blended back to the original shape
After welding, the repair was ground and blended so the corner and every rib follow the original factory shape. The goal was a repair you cannot see or feel, not just one that holds oil.
Painted to a factory finish
Once the repair was blended in, the pan was painted in a matte finish. The result looks like a factory pan: the ribs, corner and drain boss all read as original, and there is no visible sign of the repair.
Have a damaged aluminum part?
We do custom fabrication, TIG welding and 3D scanning, and we can travel to you for on-site scanning. If you have a cracked or torn aluminum part you need back quickly and looking original, get in touch and send us a photo.