(quoted from post at 22:00:41 01/10/10) Alright if you are an ok welder and familiar with 6011 and have a AC welder,I would suggest v it out,run a pass,Now grind every bit of slag out,repeat. If you are a good welder and know how to run 7018 then V it,tack it in place with good tacks and 6011 rod. Run a root pass of 6011 around it.Grind every bit of slag out,follow with 7018,multiple passes until its full of weld rounded out of the top of the V. If you see any place that has bubbles in the weld after you chip the slag,grind them out and reweld it.
Now there are other possible rods. You want to stay away from Nickel rods because they are expensive and too brittle of a weld in my opinion. If you weld nickel on there and it breaks then a pro will have to grind all that mess out of his way and use a different rod. So it will make the job a lot harder and maybe make the difference of finding somebody to do it right or not if you need to.
Also welding cast can cause it to crack. If it does then grind a v in the crack and weld it. Once you start you cant stop until you are done or it will surely crack when you try to weld on it again. You can almost eliminate cracking by welding an inch,stop,clean slag,weld another inch,repeat. You can even use a MIG. You want to fit it as close as possible back to where it was and if you cant see the crack very easy when you get it fit,thats as good as you can get it probably.
7018 is harder to weld with an AC welder but there is 7018 AC rod that works better on an AC welder. With a DC Pipeliner or something its no problem to weld 7018. There are lots of rods nowdays. You could ask where you buy them what would work for it as long as they dont talk you into buying nickel rods which are real high priced. Ask what Low Hydrogen rods they have that will work on cast steel.Nickel is actually for cast iron and not necessary for welding cast steel.MIG might be as good as any.
Before the naysayers even get started I have welded cast steel with 6011,7018 and an AC welder,higher strength Low Hydrogen which is almost the same as 7018,Mig,and other rods that I dont even remember,plus nickel. Nickel was the worst but I think it may be stronger than brazing. MIG is a little brittle but better than nickel and the easiest way to weld cast without it cracking as long as you weld a short weld,grind before starting the next weld so you start in a nice clean surface. 7018 works good,and is maybe some stronger than MIG if you can get it done without cracking. Also I grind my weld when I get done so its not so noticeable and I think it makes the weld stronger. If you are a real good welder uphill is the way or flat if you can get it that way.
You dont have anything to loose. Its broke now. If you can weld you can fix it. Even if you cant weld good you might be able to stick it together and JB Weld it to where it holds oil and get by for a while.