Frequently Asked Questions
General Questions
What is the difference between Castaloy, Alumaloy, and Steelaloy?
Each product is designed for a specific metal. Castaloy repairs cast iron at approximately 550°F. Alumaloy repairs aluminum, pot metal, and galvanized steel at approximately 728°F. Steelaloy repairs all grades of steel and copper at approximately 500°F. All three work with a standard propane torch.
Do I need a welding machine?
No. All three products work with a standard hand-held propane torch available at any hardware store for under $20. No arc welder, MIG machine, TIG machine, or oxyacetylene torch required.
Are these products made in the USA?
Yes. Every Castaloy, Alumaloy, and Steelaloy rod is manufactured entirely in the United States by Bradshaw Consulting, Inc.
Is the repair permanent?
Yes. When applied correctly with proper surface preparation, all three products create permanent repairs that are stronger than the original base metal.
Can I drill, tap, grind, or paint the repaired area?
Yes. All three alloys are fully machinable after cooling. You can drill, tap, thread, grind, file, sand, polish, and paint the repaired surface.
Alumaloy (Aluminum Repair)
Can I use Alumaloy with just a propane torch?
Yes. A standard propane torch produces more than enough heat to bring aluminum to Alumaloy's 728°F working temperature. For thicker material, a MAP gas torch works faster but is not required.
Does Alumaloy require flux?
No. Alumaloy is 100 percent fluxless. This is one of its key advantages over traditional brazing — no messy cleanup and no risk of long-term corrosion from flux residue.
What is Alumaloy's tensile strength?
Alumaloy achieves a tensile strength of 39,000 PSI and can withstand pressures up to 650 pounds per square inch — comparable to most common aluminum alloys.
Can Alumaloy repair aluminum boats?
Yes. Alumaloy is one of the most popular products for DIY aluminum boat repair. When applied correctly, it creates a completely watertight, pressure-rated seal that is stronger than the original hull material.
Is Alumaloy food safe?
Alumaloy contains no lead, no tin, and no cadmium. For items in direct prolonged contact with food, we recommend checking your local health and safety regulations before proceeding.
Can I repair a cracked aluminum pressure washer pump housing?
Yes. Remove the fitting first. Clean thoroughly with a stainless steel wire brush and acetone. Heat the casting and flow Alumaloy into the crack. Build up a small fillet around the cracked area. Once cool, the repair is watertight and stronger than the original. The repaired area can be re-drilled and tapped as needed.
Castaloy (Cast Iron Repair)
Why is cast iron so hard to weld?
Cast iron contains 2 to 4.5 percent carbon, making it extremely brittle. Traditional welding operates above 2,100°F, creating thermal stresses that cause cracking. Castaloy works at just 550°F, eliminating this problem entirely.
Does Castaloy require flux?
Yes. Castaloy works best with #7 Flux, which is sold separately or included free with qualifying bundle orders (4 or more rods).
Can Castaloy repair engine blocks and exhaust manifolds?
Yes. Engine blocks and exhaust manifolds are among the most common applications. Jeff Wilbanks repaired a Mack diesel engine block with Castaloy and saved thousands on a replacement.
Application Technique
What is the most important step?
Surface preparation. The repair area must be completely clean — no rust, paint, oil, or oxidation. Use a wire brush, sandpaper, or grinder to expose bright, clean metal at least one to two inches beyond the damage.
Should I heat the rod or the base metal?
Always heat the base metal, never the rod. When the metal is hot enough, the rod melts on contact.
What is the brushing technique for Alumaloy?
While Alumaloy is molten on the surface, scratch it into the base metal with a stainless steel wire brush. This breaks through the aluminum oxide layer and is essential for maximum bond strength.
Ordering and Shipping
How do I get free flux?
We include free #7 Flux when you order 4 or more Castaloy rods or 20 or more Steelaloy rods. Our Special Bundle packages include free flux and free shipping.
Do the rods expire?
No. All rods have an essentially unlimited shelf life when stored dry. No expiration date, no degradation.
Where do you ship from?
All orders ship from Bradshaw Consulting, Inc. in the United States. Free shipping is included with qualifying bundle orders.