Block damage What would you do?"
#61
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If it were my car...
Since you appear to still have the piece that was cracked/chipped out i would clean it up install the broken part then have a welder simply "tack" it in place. I think the key is not to introduce a lot of significant heat in one localized area of the block to prevent any significant warping..
I would tack... let it cool cool...tack...cool...and repeat and do this in several spots. You could actually seal the crack with a series of tack welds in a line along the crack....just give adequate cooling time to prevent heat build up.
As for issue 2... the mating surface with the gasket i would NOT WELD there. I would simply try and get the area as smooth as you can for a mating surface with the pan gasket. Use JB weld to "push into the exposed crack along the mating surface then sand it smooth/flush.
My block was cracked in a similar spot but not nearly as bad as that. I used JB weld to seal the crack and it been bone dry underneath for over two years...no issues.
You dont want anything to do with getting a new block unless you have the $$$ and the time for the project. There are many little costly items in a rebuild from the poitn you are at now...gaskets...seals..rings...etc etc.
Since you appear to still have the piece that was cracked/chipped out i would clean it up install the broken part then have a welder simply "tack" it in place. I think the key is not to introduce a lot of significant heat in one localized area of the block to prevent any significant warping..
I would tack... let it cool cool...tack...cool...and repeat and do this in several spots. You could actually seal the crack with a series of tack welds in a line along the crack....just give adequate cooling time to prevent heat build up.
As for issue 2... the mating surface with the gasket i would NOT WELD there. I would simply try and get the area as smooth as you can for a mating surface with the pan gasket. Use JB weld to "push into the exposed crack along the mating surface then sand it smooth/flush.
My block was cracked in a similar spot but not nearly as bad as that. I used JB weld to seal the crack and it been bone dry underneath for over two years...no issues.
You dont want anything to do with getting a new block unless you have the $$$ and the time for the project. There are many little costly items in a rebuild from the poitn you are at now...gaskets...seals..rings...etc etc.
#62
Burning Brakes
Just a tip guys when you are finished welding spread JB weld over the welded area to fill in any small holes you might have missed just some added insurance that it doesn't leak oil good luck take your time it will turn out well
Paul
Paul
#63
Captain Obvious
Super User
Super User
Tony's post is dead on........for what I would do.
#64
Three Wheelin'
if you weld it
consider using some of this to limit the heat transfer to areas like the oil pump (o ring),
front crank seal & where the block "splits"
http://store.weldingdepot.com/cgi/we.../HANDIJIG.html.
When you are done, if the pan mounting surface is a little off, TOYOTA has a great form in place gasket sealer (FPIG)
Part # 00295-00103
Per box: " toyota seal packaging 102 (fpig)
for oil pan/ camshaft housing"
front crank seal & where the block "splits"
http://store.weldingdepot.com/cgi/we.../HANDIJIG.html.
When you are done, if the pan mounting surface is a little off, TOYOTA has a great form in place gasket sealer (FPIG)
Part # 00295-00103
Per box: " toyota seal packaging 102 (fpig)
for oil pan/ camshaft housing"
#66
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Thread Starter
Post some before welding pics! Please
#68
every thing is in place and ready to weld. I made a few practice runs on scrap aluminum just in case the aircraft welder fails to make it.
I made a mock up oil pan out of some old 1/4 inch aluminum to check for fitment. All holes line up well in both the pan and the alt brkt.
I made a mock up oil pan out of some old 1/4 inch aluminum to check for fitment. All holes line up well in both the pan and the alt brkt.
Last edited by Brad W; 06-27-2013 at 12:43 AM.
#69
Dang, was just trying to up load those. Well done Brad.
#70
Race Director
since good replacement motors are pretty cheap I would just change the entire engine....its really not that hard to swap engines...I've done it TOO many times.....
#71
This has kinda turned in to a challenge for us in DFW. I can imagine that most places would just JB weld the parts back up, but Brad (being the aircraft engineer that he is) has set up jigs.........sets.........all sorts of crap. Really cool to watch.
I'm sure we could have had a new engine in there and him on the road already, but why not try something we haven't done so far? :{)
I'm sure we could have had a new engine in there and him on the road already, but why not try something we haven't done so far? :{)
#72
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Brad - Way to go.
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Does it have the "Do It Yourself" manual transmission, or the superior "Fully Equipped by Porsche" Automatic Transmission? George Layton March 2014
928 Owners are ".....a secret sect of quietly assured Porsche pragmatists who in near anonymity appreciate the prodigious, easy going prowess of the 928."
Does it have the "Do It Yourself" manual transmission, or the superior "Fully Equipped by Porsche" Automatic Transmission? George Layton March 2014
928 Owners are ".....a secret sect of quietly assured Porsche pragmatists who in near anonymity appreciate the prodigious, easy going prowess of the 928."
#74
Race Car
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Location: No where Oklahoma AKA "The Dust Bowl" In The Arm pit Of Hell
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Yep build it up with JB and just live with it. It might leak a bit but make due till the engine fails. Heck it might hold and not leak for years. It was holding when he bought the car.
#75
Burning Brakes
After all the fitting and fiddling the welding is kind of an anticlimax it goes way faster than you are dreading don't worry about the heat the aluminum transfers the heat so fast nothing close should cook to bad just watch out for radiant heat from the ark buring/melting stuff hanging close with a good modern welder this should go way easy coat the inside and outside with jb weld to seal it when its cool,clean up the pan gasket surface and you are good to go.
good luck guys
yes Imo i have done this before should be pics on here somewhere link anyone?
Paul
good luck guys
yes Imo i have done this before should be pics on here somewhere link anyone?
Paul