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Help with my early aluminum case!!

I posted this in the regular forum as well, but it seems some pretty knowlegable folks only post over here. Anyway, here's my problem.

Just purchased this 2.0S sandcast case and I'm finding a few problems. In the pics below you'll see one cylinder base has a small section broken out, so the base gasket will have little surface mating area. Find and aluminum welder to repair??

The second and third pics are another cylinder base with similar damage, but it's not missing any material. It's just bent upward and inward a bit. Is machining it smooth again an option?

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1967 911S --Bahama Yellow-- Gone
1990 C2 Targa
Old 12-16-2004, 04:43 PM
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Weld up both, reface both case halfs on a bridgport then check roundness-size of cylinder base bores.
Old 12-16-2004, 05:05 PM
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I would send it to Walt at Competition Engineering. He has all of the jigs to fix this up proper. It does need to be welded to repair. Shouldn't be that expensive, as the damage is relatively minor.

Looks like something may have fell on it in the garage, or it was dropped at some time. It's in an odd place, considering these surfaces are typically protected by protruding head studs. But, it looks like someone (unwisely) removed the studs a while ago...

-Wayne
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Old 12-16-2004, 10:36 PM
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Thanks guys, that's kind of what I figured. Seems like it's always something on this project....
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Old 12-17-2004, 09:07 AM
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Quote:
Originally posted by RetroSC
Thanks guys, that's kind of what I figured. Seems like it's always something on this project....
It'll be worth it when it's done!

-Wayne
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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming Soon:
SPEED READ: Porsche 911 (October 2018)
Old 12-17-2004, 09:42 AM
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This case was not dropped some one used a steel hammer to smack the clinders off at the base, then a wedge on the one missing material. Wayne you can not think so crude that people would do that, There our hacks out there. Good luck retosc it really is not that bad, but it does need to be fixed by a competent shop like has been said.
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Old 12-23-2004, 06:35 AM
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Yes, it does look like somebody damaged it removing the cylinders. I'm going to try and send it to Walt, but it seems he's out until after the holiday's. I may call Ollie's and see what they have to say.
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Old 12-23-2004, 07:19 AM
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hey, I thought you were only supposed to use the hammer to put it back together, am I missing something?

Jim
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Old 12-23-2004, 07:51 AM
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Hmmm, maybe I'll just hammer it back on.. Two wrong's make a right! Right?
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Old 12-23-2004, 09:07 AM
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