Broken casting

[warren casey]

I broke a small part off the block. It's a small piece of the flange on the carb side of engine, where the aft housing is pined to the block with a tapered pin. Can the Block be fixed? Can a machine shop weld it back on? It doesn't seem like a very important pin and bolt. Not a very close to the transmission.

[warren casey]

Above are some pictures of the broken part. Below are picture of the two partial engines that I will make one good engine - Rust willing!! The plan is to remove the cylinder block from the gold one and put it on the blue one. I think removing the two blocks will be very tricky. most of the bolts are rusted hard to the block.

[Don Moyer]

Warren,

Hot welding a block successfully requires meticulous heating and recooling of the whole block before and after a welding operation, to insure that the heat from the welding will not warp (or crack) the rest of the block.

You're paving new ground here, but I think (though it may look a bit "hokey") you have a good chance of getting the gasket to seal in that area by putting a 5/16" nut on the back side of the housing so you can tighten that bolt and then applying epoxy from one of the small fiberglass repair kits available form West Marine over the failed zone. We're only talking about controlling the splash effect of the crankcase oil in this area with no measurable pressure. You could even "squoosh" the broken piece back down into the fiberglass so the area will look better.

These kits from West Marine have a container of glass powder to mix with the epoxy which makes it much more adhesive.

Don

[warren casey]

Thanks Don, I like that idea. I will try it and keep you updated on the progress.

[warren casey]

The engine is almost finished - I'm picking it up today (12/5). My machinist fixed the broken piece by welding it. He used a Arch Welder with "Missile Rod" and it seemed to work great. He said he didn't have to heat the whole engine when only welding on an outside flange. As you can see in the pictures the bolt is holding and it all looks fine. I hope to run the engine soon - looking forward to running the engine. Thanks again for the help! Ken at the parts department has been a great source of information and made this rebuild move very smoothly.

[sastanley]

Wow Warren...that looks great! Since your original post to your latest, I have only managed to further dismantle my motor!

Nice job!

[warren casey]

Well - I did pay a Machinist to put the motor back together, it only cost another $600. And he had it done in a couple of weeks! I thought it was worth it because of lack of experience I have in the engine rebuilding arena. The whole thing was well worth it - I learned a lot about the engine and just had fun taking it apart. If it wasn't for the rust, things would of worked easier and faster! Rust is the enemy!

[Kelly]

Amen to that, Warren. Rust is the bane of my maintenance efforts...

Good work on the rebuild and repairs.

Kelly

[warren casey]

Here a few new pictures of rebuild progress - waiting on a few parts - new water pump! I will run the engine on the bench sometime in January 2009 before installing it in the boat.

[baileyem]

Looks good enough to be one of Don's pinups. Great looking job.

Mike

[Greg]

Warren,

Beautiful job. I really like the original color. Did you spray it or find brush on ?

I just bought a 72' Ericson 32 .. all was fine moving to it's new home when we lost compression in 3 & 4 . Looks like it was the dreaded green head gasket. Ken was very helpful with my parts order as well. Now my mechanic is urging me to pull the motor for ease of things. I have to do rear motor mounts and address the engine beds, so I might as well. I pulled my gas tank already.

My question is can you detail how you pulled it. Did you remove the wood cabinetry around the engine access hatch ? How did you set up your hoist and get it to the cockpit .. and from the cockpit to the dock ? Any pictures ?

I'd very much appreciate hearing how it went. It will help me do a really nice job on my engine by bringing it home. Looks like it was re-built 200 hours or so ago but rust is taking over. Now's the time to get it dialed.

You can email me off list at gregrohde@gmail.com

Congrats on a great job .. good time of year to get it back in the boat.

Regards, Greg

[lat 64]

Greg,
I got lots of good ideas about lifting the engine from the forum archives. So when I took mine out just after Christmas I took lots of photos to share the process, for good or bad. It went well. I will make some kind of sequence out of them in a reasonable file size and post it here soon.

Russ

[Greg]

Russ,

It would be great to see your shots before I go at it in a few weeks. I just started following your remodel .. with interest.

Way to Man-up .. that's a level of cold I'm not accustomed to

Regards, Greg