Welding & Machining Solutions | High Velocity Technologies

Confident repair of impact damage in cast iron without realigning or rebuilding

When a CAT 793F Converter Housing (488 – 1788) made its way to HVT for repair, the damage ran deeper than expected. It had suffered a full face collapse at a mounting point. One of the bolt holes had split, and the connecting face had shifted several millimetres out of plane. With the housing made from grey cast iron, the margin for error was zero.

The client was already on a tight schedule and budget meaning this was a high risk job. HVT delivered a structural repair that not only restored the mounting face but protected every alignment feature that mattered: PCD, bores, dowels and seal interfaces.

The trouble: Cracked mounting, collapsed face, cast iron complications

The damage included:

A fractured bolt hole at the torque converter mounting point.
A distorted face, out by several millimetres from spec.
High risk of distorting surrounding features (PCD, bores, dowels, connectors) if not controlled properly.
This wasn’t a weld-and-go job. The cast iron bare required specialised techniques, and the interconnected alignments left no room for distortion.

The solution: Controlled weld, structural reset

HVT applied a cast iron repair process built for stability;

Crack was fully excavated and prepped for welding.
Collapsed face reset using reinforced bracing and staged heat control.
Weld sequences designed to manage thermal stress across the housing.
All key alignment surfaces stabilised using precision fixtures and jigs.

As part of the process, interpass temperatures were monitored to ensure dimensional accuracy. The goal wasn’t just to fix the crack, it was to avoid secondary damage.

The final result: Stabilised and ready to go

Crack closed and face returned to OEM tolerance.
PCD, bores and dowel alignments held throughout the process.
Minimal post-machining required. No rework or build.
Client avoided major delays and full replacement cost.

Dimensional checks confirmed this part met spec. The component was returned field-ready, with every alignment point preserved.

When cast repairs matter, experience makes the difference

Most shops avoid cast iron repairs for a reason. It’s unforgiving, especially when tolerances matter. HVT’s disciplined process turned a high-risk job into a clean, functional recovery.

Let HVT show you what’s possible when you control every variable in the repair.

Confident repair of impact damage in cast iron without realigning or rebuilding

The trouble: Cracked mounting, collapsed face, cast iron complications

The solution: Controlled weld, structural reset

The final result: Stabilised and ready to go

When cast repairs matter, experience makes the difference

Contact Our Team