Broken Cast Aluminum Part - Can it be welded?

[Charlestonboxster]

Car is 1998 986

Mistake #1: Passenger side seatbelt assembly was not working well, belt not retracting, so I unscrewed it from the frame to

play around with it. I twas still dangling up near the belt loop.

Mistake #2: A bit later, I opened the top, while it was opening, the dangling seatbelt assembly was in the way of the opening top mechanism, top opening started to slow down and CRACK!!! Something broke.

I have the autotop button, but was paying attention, and stopped the opening procedure.

Opened and closed slowly a few times to diagnose, right side does not follow along as it should about 3/4 of the way open,

looking deeper into why, and found that:

Part # 986-561-34600, steering arm lower, a cast aluminum part about maybe 8" long x 2" wide, has literally broke in two, severed in two in the middle area (not broke where there is a bolt hole, just the arm part).

Porsche PET Illustration # 811-05 shows the part, #11.

When the Germans say "very strong motor"..., they sure are right!

My primary question, being a boxster on a budget owner, is

- Can an aluminum part like this be welded back together by a welder (probably $25), instead of buying a new one?

Sunset part is $217+ship and sticking delay, parts guy said the cast part "might" be weldable by a pro who knows what he's doing, as it's a metal that gets soft when heated.

No Jin, I won't try crazy glue:)

I have yet to attempt to remove the part, I'm assuming the best way is to remove the top assembly from the the car first

"A la Maurice" instructions, and hope I can remove said part to either have it welded, or replaced.

Thanks for any advice as to;

1- Whether this part should be repairable or not

2- Anything I need to know in trying to replace it (remove top from car or not, potential problems, etc..), with welded part or replacement.

Sidenote and off topic: The seatbelt still won't come out of the assembly, it's stuck all the way in, have removed it from the car, have not taken it apart yet, any experience on this problem is welcome too.

Edited July 28, 2008 by Charlestonboxster

[Charlestonboxster]

Ok,

I have researched that it certainly should be weldable, but knowing exactly what type of ally it is would help the welder.

http://www.welding-advisers.com/Material-identification.html

Therefore the million dollar question: Anyone have any how to find out what the alloy type is for this part?

I imagine it's identical to the other similar convertible top mechanism cast aluminum parts.

The more info I can bring to the welder, the better, I'm sure.

Tks!

Tony

Edited July 29, 2008 by Charlestonboxster

[Tool Pants]

Porsche says the top frame is magnesium. I have no clue if your broken part is magnesium or aluminum, or how to tell.

If you needed a very expensive part for the frame I would say check with the Boxster spec racing guys because they remove the top and have no need for it. If it can be welded and fails again then you have to do this twice. If it were my car for $217 I would replace the part.

There is a local 2.5 owner who broke the mounting lug on the frame where the push rod mounts to open and close the top. He replaced the entire frame. The part he broke is different than your part. I dont't know what he did with his old frame. If he still has it then maybe you can buy the part from him. Mikes box. He recently sold his 1997.

http://www.renntech.org/forums/index.php?s...mp;#entry101635

[Charlestonboxster]

Porsche says the top frame is magnesium. I have no clue if your broken part is magnesium or aluminum, or how to tell.

If you needed a very expensive part for the frame I would say check with the Boxster spec racing guys because they remove the top and have no need for it. If it can be welded and fails again then you have to do this twice. If it were my car for $217 I would replace the part.

There is a local 2.5 owner who broke the mounting lug on the frame where the push rod mounts to open and close the top. He replaced the entire frame. The part he broke is different than your part. I dont't know what he did with his old frame. If he still has it then maybe you can buy the part from him. Mikes box. He recently sold his 1997.

http://www.renntech.org/forums/index.php?s...mp;#entry101635

Wow, magnesium may be a whole other ball of wax, thanks for the insight, and

I PM'd Mike to see if he still has his top.

If not, I won't screw around, I'll order the part.

Many thanks TP

Tony