Well, it's not like he's welding cast "iron" now is he? Cast aluminum isn't that bad if you've got a TIG welder, just set up the wave balance to "clean" the cast out a little bit as you're welding, and use good rod.
Honestly, if you've got a bit of time and some extra aluminium laying around, this would cost like $15 tops in rod/gas/electricity bill. (not including the metal pricing)
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Rotaries:They are NOT that complicated!
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