If I needed to repair a side cover, I would clean it the best I can, then go for it.
I don't have an ultrasonic cleaner, or even a parts washer. I could spend a lot of time with acetone and a brush, but it's not going to clean out the decades of grime from the screw holes.
Decided to get a workout and cut some (easy to clean) coupons by hand, since I'm just practicing/learning.
Well, it's definitely different. Started at 125 amps, then 100, ended up at 65 which might be a bit low. Instructor gave me some unknown number filler rod which was shit. I used 4043, but the beads look porous. Was trying to get some 4047, but it's pretty hard to find. Might have to give Roger a call and see what he uses.
For sure, it's the most difficult type of welding I've tried. The large craters are where I tried the shit rod. Still have more cast aluminum to work on. Thanks, Larry! Also want to try welding cast aluminum to billet.