How Would You Fix It?
 

I found this old (1985) Yamaha 4hp outboard under my dad's back porch. He used it for about 10 hours and then just stuffed it in the shed. I changed the fuel and plug and put it in a barrel of water and it started on the 3rd pull. It was running well until I noticed some water coming out from under the engine cover at the rear. I took the cover off and discovered this giant hole on the side of the block (see attached picture).

It's actually the outside of the water jacket that surrounds the cylinder. I cleaned out tons of sand and silt and attempted a repair with J-B Weld and it worked for about 20 minutes and then water started to weep through.

Any idea's or is it total junk? Can aluminum be welded on this type of application?

Thanks guys,

Maxhttp://forums.pelicanparts.com/uploa...1245962738.jpg
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JBWeld

+1

Already went the J-B weld route as the "after" photo's (last 2) show. It did a good job and I sanded and painted it the factory color. It looks great but unfortunately the water weeps through. I sanded it down and applied another coat of JB Weld only to have it seep again. http://forums.pelicanparts.com/uploa...1245964432.jpghttp://forums.pelicanparts.com/uploa...1245964472.jpg

You could try this product.

Lumaweld

I think they sell it at Lowes or Home Depot.

There are different varieties of jbweld, as well.

Not sure why JB didn't work. I have repaired motorcycle engine cases with it and had it hold for years.

A little leak isn't going to hurt, you do have an endless supply of water.

repaired a trans cover on a harley in the 70's with Alumaweld after knocking a gear or two thru it. worked fine and could barely see the repair after buffing it out. good thing too since it wasn't my bike

Good point. I was going to try and sell it as I have no use for it. J-B Weld also makes a "WATERWELD" product. Maybe I'll give that a shot next. I've got nothing to lose.

I'm pretty sure that could be welded but you'd need to get it cleaned up well and find an experienced aluminum welder.

I used to work with a guy who was an ace welder. It used to be said the only things Ricky couldn't weld were a broken heart and the crack of dawn.

Try to use a shop vac to suck the JB Weld into the pores.

In my RX-7 I opted to port the intake ports aggressively, this meant we would touch into the water jackets, well... my mechanic got a little too aggressive with the porting and we made some nice size holes int he jackets.

He tried all kinds of space aged, fancy, expensive, epoxies etc... every one failed. We used JB weld and it is still holding strong 10K miles later.... and lots of abusive driving.

He used a shop vac to pull the JB Weld into the joint so it seeped through and was not just on the surface.

That could be TIG welded by some one that knows what their doing, I would check in to that.

I love JB weld on non mechanical (Engine) the problem is your never going to stop thinking about it being there when you are miles down the lake.

It may not take the heat cycling very well. That type of part expands and contracts more than you may realize. The metal is expanding with the engine heat the cool water is causing contraction = Failure.

Weld it you will never worry about it.