SOT: how is this made?, need to mod... Options

[Chris914n6]

I need to clock the steel tube to clear the trunk.

I'm guessing it's pressed into heated aluminum, maybe with a lube that turns into a glue?

Anyone know for sure? @Superhawk996 maybe?

I have a 1500F heat gun to work with.

(IMG:http://www.914world.com/bbs2/uploads_offsite/live.staticflickr.com-431-1677898518.1.jpg)

[Superhawk996]

Not sure what part this is. Subaru coolant crossover pipe?

Without seeing the part from other angles or knowing exactly what it is I’ll take an educated guess.

Assumption:
Cast aluminum tube with steel elbow

I’m going to say the steel elbow is likely to be cast into the aluminum and probably has an anchoring and/or anti rotation feature within the casting.

Rationale:
Looking at the picture, it seems like there is no machine work visible to square off the aluminum casting right below the “bead” around the base of the steel elbow. I also don’t see any hint of a chamfer or machine work that would be wanted if the steel elbow were pressed into the aluminum after the aluminum was cast.

Heat shrinking and a press fit would leave some opportunity for difference in thermal expansion to cause a leak or to allow the fitting to slip. I suspect the steel elbow has some features like a knurled serration or multiple beads like the one you can see, around the steel tube to allow the casting to grip it permanently and to seal it.

Casting steel features into aluminum castings is pretty common. Example cast iron liners cast into an aluminum block. It’s certainly not uncommon to cast in metal sleeves and nipples into things like water pump housings.

Being limited to a heat gun probably means you are going to struggle to get the aluminum hot enough to even try to swivel the elbow. Aluminum is a great conductor of heat and it’s going to suck the heat away from the local area you’re trying to get hot. You can try - not likely to hurt anything.

I agree with post above. The easiest approach is to remove the elbow, drill out a remnants of the steel tube, and then tap it for a fitting.

You could also cut the elbow off, orient it as you need it, index the parts, and then have someone weld the reoriented elbow back together. This would be my approach if I were in your situation. I don’t like fittings that can leak if that can be avoided.