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How to Repair Cast Iron Without Welding -Carbon Fibre Composite Repair on Bridgeport Milling Machine

How to repair Cast Iron without welding is a common problem for many people. In this video I will show you another way to repair cast iron without welding. Composite repair involves using multiple materials to strengthen a broken part. In this case Carbon fibre composite repair is used to repair a broken cast iron lead screw nut housing from a Bridgeport milling machine. Composite repair does not have to be Carbon Fibre though, other materials can be used such as: Fibreglass, wood, metal, plastics; It all depends on the job that you need to do.The Bridgeport milling machine is from my home workshop and the part got damaged while I was ironically trying to fix another problem. Composite repair of cast iron is a simple process where a glue, in this case epoxy, is used to attach carbon fibre to the broken cast iron part. The carbon fibre provides the strength and the epoxy holds the fibres in places and glues them to the cast iron. Normally broken cast iron is welded back together, however, in this case that type of repair was not an option due to the complexity of the part and risk of further damage. Using composites removes the need for welding and the issues associated with it. The bridgeport milling machine is now back together and working again.

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Disclaimer: This video is meant for educational and entertainment purposes only. It is in no way meant to be a set of instructions and therefore no attempt should be made by any party to recreate what has been seen in this video. Any attempt to do so is done completely at your own risk.


  1. This was very useful thank you. I've got a break on a large 4 foot cst iron French 18th century crucifix and one of the cruciform arms has broken off… so can't think of a solution to reattach it as there is such a small surface area between the two pieces… obviously cant weld as its cast iron but this method might help thanks.

  2. I think you need nonstick material (e.g. film) to take off that small piece easily.

  3. Can you give us an update on how that repair is holding up?

  4. I've used synthetic non woven fabric and epoxy to fix broken plastic parts, it works a treat and really adds strength to the repair.

  5. Heat the part up in an oven Then use nickel welding rod Cool part off in sand very slowlyThen reshape it accordingly

  6. Do you think fiber glass cloth would have similar effect?

  7. Would this work for a car repair? The block of the engine is Aluminum I need to make a repair where you screw & mount the alternator since it cracked off & that’s part of the engine too. Keeping in mind it’s right next to the cylinders that go into the engine & they get really hot when running the car.

  8. I am considering this as a possible option to repair a cracked trunnion in a 1940's Walker-Turner table saw that I'm restoring on my own channel. Can you tell me how I would find similar carbon fibers, like what terms I might use in a search query? How's your repair holding up? Thanks for sharing this technique! Cheers!

  9. Did you put any epoxy in the crack before attaching the two pieces or just around it? I have to repair my mailbox where the aluminum pieces broke away from the pole.

  10. Here we are a year later, has it held up?! I hope so because I'm going for it, on a cast iron part, tomorrow.

  11. Nicely done presentation. I'd never used JB Weld on a significant repair, and I'm glad I watched this before I tried.

  12. Thank you for this! I was trying to figure out how to repair my old treadle sewing machine leg that snapped off, without having to hire someone to weld it. This seems much cheaper lol

  13. Wouldn’t it have made more sense to glue at least a layer of fiber then add more after adding the resin? Just a thought more control. Good video though, I will use the approach.

  14. Please tell me the name of the chemical

  15. Carbon fibres with JB weld 😀 😀 😀

  16. Your are a genius ,Great procedure ,Great job

  17. Try using Belzona 9411 (Release agent for epoxy resin) on aluminum inserts and remove them when the resin is cured.

  18. I can not understand why the factory did not fix this design. Remember making one out of steel billet. The piece is just fine.

  19. If only there was a basalt or carbon equivalent of 3M's Bondoglass. Bondoglass IMO appears fire retardant because of talc and fiberglass strands.

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