3800 cylinder repair.
I picked up a 3800 last Fall and the PO had broken one of the carb adapter screws off in the cylinder and messed up the intake port on the cylinder trying to remove it.
I don't have access to a machine shop and someone who can weld aluminum.
Here's what I did in case anyone else comes across a similar issue.
To anyone new to the forum that reads this.
DON'T try this with magnesium!
I got a Benzomatic MAP gas torch and some of their aluminum rods.
Here's the before pic. I did file out the broken area to get down to good metal and remove the oxide.
The soldered up port flange. The screw is in there to give continuity with the existing threads and keep the hole open.
I filed the solder down even with the original. There are a few inclusions and it isn't too pretty but it's flat and it saved the cylinder. The aluminum rods work at around 700 to 750F. It's about the same hardness as the original material.
A regular propane torch didn't work for me because the aluminum cylinder is too much of a heat sink and I couldn't get enough heat to it.