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Machining/Casting aluminum cooler covers

Discussion in 'Engines' started by CTdave, Aug 16, 2023.

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  1. CTdave, Aug 16, 2023
    #1
    CTdave

    CTdave Senior Member

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    I've been searching for two aluminum Charge Air cooler covers for an MTU 12v183. Both sides are corroded and have to be replaced They're no longer available from MTU so I've been hitting Aluminum casting foundries and C&C machine shops in CT and NY. I've been to six or seven but nobody is interested. The big shops all want to fabricate hundreds and the specialty shops don't seem interested.

    **The pictures are of one that I found on Ebay but it's from a TE92, not 93 & it's about an inch shorter. Once I find a shop, I'll take one off & send it to be matched.

    I've also tried Strike Marine and another place in Ft. Lauderdale (both deal in used diesel engines/parts) but no luck there.

    It doesn't even have to get this technical. The raised areas at each bolt hole don't have to be machined like that, it can all be flush/even. There is nothing that attaches to these and there are no clearance issues

    Anyone ever had specialty aluminum parts either cast or machined? If so, who did you use?

    Thanks!

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    Last edited: Aug 16, 2023
  2. Capt Ralph, Aug 16, 2023
    #2
    Capt Ralph

    Capt Ralph Senior Member

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    So, what is wrong with the one in the photos?
  3. YachtForums, Aug 16, 2023
    #3
    YachtForums

    YachtForums Administrator

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    Dave,

    These are simple, no-pull sand cast parts that could be easily scanned and output to a 3D printer giving you a pattern for a lost wax process. There are foundries that will pour one-off parts. Because it's a small part and easy to ship, there's no need to stay local. Maybe venture a call to Perko in Miami. They have an in-house foundry and might consider a single pour. 305.621.7525
  4. Steve in SoCal, Aug 16, 2023
    #4
    Steve in SoCal

    Steve in SoCal Member

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    That could be easily machined from solid not cast, a pattern and all the expense in casting a one off is not really worth it in a simple part like this.
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  5. CTdave, Aug 17, 2023
    #5
    CTdave

    CTdave Senior Member

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    The pictures are of one that I found on Ebay but it's from a TE92, not 93 & it's about an inch shorter. Once I find a shop, I'll take one off & send it to be matched
  6. CTdave, Aug 17, 2023
    #6
    CTdave

    CTdave Senior Member

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    Thanks Carl! I'll give them a try
  7. CTdave, Aug 17, 2023
    #7
    CTdave

    CTdave Senior Member

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    This was my first thought. I just haven't found a machine shop that'll do it. Still looking & will also try Perko as Carl mentioned
  8. Bob Quinn, Aug 21, 2023
    #8
    Bob Quinn

    Bob Quinn New Member

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    I have a CNC shop in Michigan, I might be able to do that. I'm not the cheapest on the planet but I'm pretty good at reverse engineering stuff like this.
    My cell is 586 six one zero 4493

    I also have a buddy with a couple 3d printers, we were talking about the 3d printed wax the other day. I sent him a screen shot to see what he thinks.
    Last edited: Aug 21, 2023
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  9. Bob Quinn, Aug 22, 2023
    #9
    Bob Quinn

    Bob Quinn New Member

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    My friend says he can do a lost wax pattern if it is less than 10 x 10, he is looking into price.
    Let me know on the size if you can. The one in the pic looks slightly over 10 in one direction. Are yours the same size?