Magna Jig Saw Cracked mounting tubes

[bob84]

I have an old Magna 18 inch Jig Saw.

It fell and cracked one of the holes on the bottom of the unit that the mounting tubes go up into.

This would be made of cast aluminum, correct?

Any ideas would be appreciated. I don't think JB weld would do because of the extreme vibrations.
I did wonder if the following product would work to fix it, using a Mapp gas torch, but it has been years since I welded with oxyacetylene:
"Hobart 770206 Brazing Rod, 1/8-Inch by 18-Inch, Quantity-7, Aluminum"
The big internet shopping site that starts with an "A" sells it and harbor fright stores sell a slightly similar product.

Any suggestions on methods to weld, fix or worst case scenario . . . should I just forget about fixing it?
All ideas would be appreciated.
Thanks
Bob

[joedw00]

Pictures would help.

[bob84]

Jig Saw 03A IMG_1755.JPG (129.91 KiB) Viewed 4231 times

[JPG]

Bummer!

I would be inclined to try strapping both above and below the set screw(all the way around the base-squeeze both sides).

It must have been dropped since I do not think normal operation is very stressful.(why I think strapping may suffice)

[Hobbyman2]

It could be welded,, a wire feed using aluminum wire and argon gas inside and out ,,, but then it would also need to be machined again inside the hole ,,so the cost to repair would be a toss up,,,, unless you know some one who could do it.

IMO I would just look for a replacement.

Good luck

[JPG]

ORRRRR, A gross 'fix'.

With the tubes installed as they need to be:

Drill a tap drill size through both the broken casting and through the post.

Drill a clearance size hole through the casting only(stop when bit contacts the post).

Tap the hole in the post.

Install screw into newly tapped hole and tighten.

Hole needs to be perpendicular to crack face(screw will pull the crack faces together).

Repeat as needed in different location(I think 2 will suffice one above and one below the set screw).

Not pretty, but even though the post is drilled/tapped, it is still serviceable.

P.S. You may need to clean out any crud buildup in the crack and between the casting and the tube. Also loosen the set screw when tightening the new screws. Retighten the set screw when done.

[thunderbirdbat]

Also, drill a small hole at the end of the crack to stop it from spreading further.