Welding a block back together

[AuSpec Vr4]

Hey all

Long story short, broke a flywheel couple years ago, cracked an ear off the block and snapped a bolt inside the top bell housing hole of the block. Which has a crack also, what are my options? Safe to re weld the bottom ear back on and extract the other bolt/weld the crack?

 

[4piknup]

That ear is a very specialist job.
i was just watching a jay leno/ mr.tig clip about special tig rods for cast without preheat. Otherwise you have to preheat block pre welding. I still dont think you would get it good enough to hold a thread.
Id junk it. Sonata 6bolts are cheap blocks. Just add the squirters if you want them

 

[ENGINR]

bazeng had a block welded up by a guy here in Vic. This bloke is an absolute magician when it comes to metal work and fabrication, but it shows that welding the block up can be done by somebody who knows what they're doing.

 

[4piknup]

Brazing and a helicoil might hold on the ear. Brazing and helicoil on the crack as well.
brazing cast is good as it gets all the way through the crack and it doesnt really have a weld affected zone.
Im no expert on welding.

 

[Benzo4gT]

I have a sonata 6-bolt in my shed, I wanted a few hundred for it, but now I just want the head and a few other bits off it. If you only want the block/bottom end I could drop it down for fuel.

Might drag Ian along and make it worth the trip to line up a cruise or a bite to eat at the usual place with you Brissy boys.

 

[AuSpec Vr4]

Is it a 2.4?

 

[4piknup]

Will need to drill and tap the block for a knock sensor too. The boss is there, just not machined

 

[Benzo4gT]

Is it a 2.4?

No, if it was I'd be keeping it

 

[AuSpec Vr4]

Oh haha okay well mines a 2.4 and we all know how hard to find a 6 bolt 2.4 block is to find that's why I'm repairing this one

 

[4piknup]

There was that brand new 2.4 block up for sale.

 

[AuSpec Vr4]

I could build a nice 2.0l for the price of that one block haha

 

[4piknup]

I would think it would cost 3/4 of that at least to fix your block. After brazing, you have to machine the back of the block, and then if you helicoil it you have to accurately drill and tap the holes. Thats after a good hour or so on the bbq getting preheated and should have the same cooldown.
Its got to be 3/4 day job.

You would only need to buy shorty pistons if you put your crank in benzos block, and you would be having to buy turbo pistons anyway.

 

[AuSpec Vr4]

My 2.4 is built as it is, I just need that block repaired, I trust my machine shop, if it costs 500 I'm not concerned

 

[bazeng]

I had a small crack where the sump bolts were. Very small hairline.

I called bjp (the dude who also did dougmos fabrication) and he welded it up for me while still on the car. So no preheating and no issue so far. But not a structural part.

 

[AuSpec Vr4]

I believe I should be okay, it's been on my list for a while now though, but the important part is getting the car painted. anyone have good painters they can vouch for? And not empty my bank account etc,